CA741

Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.
CE344

The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

WARNING
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

1999, Mercury Marine The following are registered trademarks of Brunswick Corporation: Autoblend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.

Printed in U.S.A.

 1999, Mercury Marine

The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation. Mercury Marine Fond du Lac, Wisconsin, U.S.A.

Diesel Engines - Inboard Models

WARNING

90 860096990 1099

CA753

WELCOME!

You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our MerCruiser products. We sincerely hope your boating will be pleasant! CONSUMER AFFAIRS DEPARTMENT

2

CE351

Identification Record
Please record the following information that pertains to your power package:
1. Engine Model and Horsepower 2. Transom Assembly Serial Number (Sterndrive) 3. Transmission Model (Inboard) 4. Propeller Number 5. Hull Identification Number (HIN) 6. Boat Manufacturer 7. Exhaust Gas Emissions Certificate Number (Europe Only) Boat Model Length Purchase Date Pitch Diameter Gear Ratio Transmission Serial Number Gear Ratio Sterndrive Unit Serial Number Engine Serial Number

Serial Numbers
The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your MerCruiser power package. When contacting your Authorized MerCruiser Dealer about service, always specify model and serial numbers.

SERIAL NUMBER

BSO/SAV
BRUNSWICK CORP. FOND DU LAC,WIS. 54935 U.S.A.

7 (D-Tronic)

1
7

3

71778

3

3

5 4
BSO/SAV

1

71935

71038

7

3

. . . . . . . . . . 2 Identification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting. . . . . . . . . . . End of First Season Checkup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing EDI Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do-It-Yourself Maintenance Suggestions . . . . . . . . Protecting People In The Water . . . . . . . . .2L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Hour Checkup . . . . . . . . . . . . . . . . . Launching and Boat Operation Care . .2L D-Tronic . . . . . . . . . .8L D-Tronic and D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warranty Coverage and Exclusion . . . . . . . . Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom Of Boat . . . . . . . . . . . . . .2L LD . . . . . . . 6 International Owner Registration . . . . . . . . . . . . . . . . . . . . . . Replacement Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Transferable Warranty . . . . . . . . . . . . . . . . . . . . . . . . . and D4. . .D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attention Required After Submersion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shifting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CE387 TABLE OF CONTENTS Page Warranty Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drain Plug and Bilge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2L. . . . . . . . . . .D2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2L D-Tronic . . . . . . . . . . Starting. . . . 11 Read This Manual Thoroughly General Information 13 14 14 17 18 19 20 21 21 Lanyard Stop Switch . . . . .6L. . . . . . . . . . . . . . . .D3. . . . . . . . . . . . D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WELCOME! . . . . . . . . . . . . . . . . . . . . Freezing Temperature And Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple EDI Engine Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warranty Information 6 Owner Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Boating Suggestions . . . . Operation 33 33 35 41 44 45 48 Quicksilver Instruments and Instrumentation . . . . . . . . . . . . . . . . . How Elevation and Climate Affect Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Important Information 25 25 27 27 27 28 28 28 28 29 29 30 31 31 31 Operation and Maintenance . . . . . 4 . . . . . . . . After Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wave And Wake Jumping . . . . . . . . . . Electrical System Overload Protection . . . . . . . . . . . . . .2L LD . . . . . . . . . . . . . . . . . . . . Impact With Underwater Hazards . Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Mercruiser Diesel Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-Speed And High-Performance Boat Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stolen Power Package . . . . . . . . . . Engine Break-In . . . . . . . . . . . Shifting and Stopping . . . . . . . . . . . . . . . . . . . . Conditions Affecting Operation 22 22 22 23 24 Weight Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8L D-Tronic and D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page Specifications 49 49 49 49 50 51 51 52 55 Seacock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather or Extended Storage 89 89 89 91 95 Battery Winter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Package Layup . . . . . . . . . . . . . . . . . . . . . . . .D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . Service Away From Home . . . . . . . . . . . . . . . . . . . . . . . . Seawater Pump Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts And Accessories Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Package Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seawater Strainer . . Ordering Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Cleaning / Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owner’s Logbook 105 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing Seawater Cooling System . . Maintenance Aids . . . Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Quicksilver Seawater Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6L Engines . . Checking Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Specifications . . . . . . . . . . . . . . . . . . . . . Anti-Freeze/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Maintenance . . . . . . . . . . . . . . Customer Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resolving A Problem . . . . . . . . . . . . . . . Except D3. . Routine Maintenance * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion And Corrosion Protection . . . . . . . . Draining Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Owner Service Assistance 96 100 100 100 100 100 101 102 104 Local Repair Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . Mercury Marine Service Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Capacities . . . . . .6L Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belts . . . . . . . . . .All Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 56 56 56 57 57 58 61 65 71 71 73 74 77 83 83 85 87 87 General Information . . . Diesel Fuel In Cold Weather . . . . .

date of sale. He will attach it to your warranty claim form. you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification. It must be presented to the servicing dealer should warranty service be required. product model and serial number(s). The dealer also certifies that you are the original purchaser and user of the product. The product warranty is not effective until the product is registered at the factory. Upon receipt of the Warranty Registration Card at the factory. present the temporary registration card to the dealer. type of use and selling dealer’s code. • • • • NOTICE: Registration lists must be maintained by factory and dealer on marine products sold in the United 6 . States. Because of your selling dealer’s continuing personal interest in your satisfaction. please contact your selling dealer. A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period. name and address. the product should be returned to him for warranty service.CD54 Warranty Information CD55 Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the • • • factory immediately upon sale of the new product. Warranty claims will not be accepted without presentation of this card. If your plastic card is not received within 30 days from date of new product sale. It identifies name and address of the original purchaser. should notification under the federal boat safety act be required.

The distributor/dealer also certifies that you are the original purchaser and user of the product. MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer. This card represents your factory registration identification. refer to the “International Warranty.CD56 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the • • distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. the Marine Power Service Center will issue you a permanent (plastic) Warranty Registration Card within 30 days after receiving the “Factory Copy” of the Warranty Registration Card from your distributor/dealer If you receive a plastic Warranty Registration Card.” • • IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. designated as the “Purchaser’s Copy”. 7 .” Refer to “Table of Contents. product model and serial number(s). date of sale. and should be retained by you for future use when required Should you ever require warranty service on this product. For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing. name and address. In some countries. you may discard the “Purchaser’s Copy” that you received from the distributor/dealer when you purchased the product. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. A copy of the Warranty Registration Card. your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form(s). type of use and the selling distributors/dealer’s code number. Make sure your dealer/distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area. The Warranty Registration Card identifies your name and address. Ask your distributor/dealer if this plastic card program applies to you.

2) Use of a propeller not properly suited to application/boat load or. is transferable to subsequent purchasers. VI. Wide-Open-Throttle operation is limited to less that 10% of operating time. and continuous cruising rpm is limited to at or less than 90% of Wide-Open-Throttle rpm. abnormal operation. adjustments. oils. We warrant each new production MerCruiser Diesel Sterndrive Power Package. whichever occurs first. The warranty period for Pleasure Craft applications is one (1) year from date of sale to the first purchaser or user of the product. tune-ups or to damage caused by: 1) Neglect. after 100 hours of engine operation. manufactured by MerCruiser (hereafter referred to as the “Company”). or 9) Use or operation of the product in a manner inconsistent with the “Recommended Operation/Duty Cycle” section of the Operation. lubricants or coolants/coolant additives which are not suitable for use with the Product or recommended by us. or in an enterprise or venture in which revenue (in any amount) is generated directly or indirectly. and Canada). or Distributor Service Office (outside the U. to be free from defects in material and workmanship. then the warranty shall be the minimum period required by law.A. 4) Operation with fuels. III. or professional entertainment activity. Light-Duty Craft is defined as a planing hull vessel used in law enforcement. it does not apply to normal wear. accident. and Canada) or to a Marine Power International Branch. lack of maintenance. This warranty shall become effective upon the date of sale to the first purchaser or user of the Product. The warranty period for Light-Duty Craft applications is one (1) year from date of sale to the first purchaser or user of the product. or the accumulation of 500 hours of engine operation. It is a condition for the continuation of this warranty that the Product be taken to an authorized MerCruiser Service Dealer. For purposes of this warranty Pleasure Craft is defined as a recreational planing craft used exclusively for pleasure and recreation. Purchaser must provide proof of purchase and substantiate the original date of sale by presenting to the dealer. 3) Use of an accessory or part not manufactured or sold by us. Maintenance and Warranty Manual.A. The unused period of the applicable warranty. Warranty claims will not be accepted by the dealer until the original date of sale and Product serial number can be verified. failure to follow instructions in applicable service and warranty information manuals or operation and maintenance manual. must be prop- erly completed by the selling dealer and forwarded immediately after the sale to Mercury Marine (U. if any. This warranty shall apply only to pleasure craft and light-duty craft applications. A copy of the dealer service work order must be retained as evidence of the completion of this requirement.CD600 Warranty Policy Mercruiser Diesel Limited Warranty I. 5) Participating in or preparing for racing or other competitive activity or operating with racing type lower unit.S. Light-Duty Craft is further defined as having an annual operating time not to exceed 500 hours. the original purchaser’s copy of the “Warranty Registration Card” or the “Owner Warranty Registration Card”. 7) Water entering engine cylinder/s through the exhaust system or air intake system. the “Warranty Registration Card”. V.S. 8 . To validate the warranty. If either of these items is not available. included with each Product. If the applicable law prohibits limitation of warranty coverage to one (1) year. Inboard Engine and Accessories attached thereto (hereafter referred to as “Product”). for required checks and adjustments. 6) Alteration or removal of parts. II. IV. commercial. but only when the customer purchases or obtains predelivery service from a Dealer authorized by us to distribute MerCruiser Product in the country in which the sale or predelivery service occurred. 8) Use of product in a full-displacement or semi-displacement hull vessel. but not later than 150 hours. improper installation or service. authorized to service the Product. Since this warranty applies to defects in material or workmanship. purchaser must provide a copy of the original purchaser’s “Bill of Sale” (Sales Contract) for the Product to be serviced.

We reserve the right to improve the design of any Product without assuming any obligation to modify any Product previously manufactured. XI. This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state and country to country. SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU.S. If purchaser cannot deliver Product to such authorized dealer. Our sole and exclusive obligation under this warranty shall be limited to repairing a defective part or. Purchaser shall pay for all related transportation charges and/or travel time. provided such service is covered under this warranty.Mercruiser Diesel Limited Warranty (Continued) VII. or other consequential damages. 9 . inconvenience. This warranty will not apply to: 1) Haul-out.A. under this warranty. he may give notice in writing to the Company (U. or the performance of service. and Canada). towing and storage charges. does not extend the period of this warranty beyond its original expiration date. launch. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY. at our option. SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES. and Canada) or the nearest Marine Power International Branch or Distributor Service Office (outside the U. The repair or replacement of parts. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY. Reasonable access must be provided to the Product for warranty service. VIII.S. If the service is not covered by this warranty. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY.A. Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid. or 2) Removal and/or replacement of boat partitions or material because of boat design for necessary access to the Product. telephone or rental charges of any type. and any other expenses associated with that service. or loss of time or income. purchaser shall pay for all related labor and material. refunding the purchase price or replacing such part or parts with new or Mercury certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this warranty. X. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer authorized to service the Product. IX. We shall then arrange for the inspection and repair.

• Water entering the engine via the air filter or exhaust system or submersion. are covered under warranty. accidents normal wear and a variety of other causes that affect the product are not covered. If diagnosis indicates a serious internal engine condition which could result in a failure. WARRANTY DOES NOT APPLY TO THE FOLLOWING: • Minor adjustments or checks. accident. etc. • Engine noise does not necessarily indicate a serious engine problem. • Use of fuels and lubricants which are not suitable for use with or on the product.. • Additional service work requested by customer other than that necessary to satisfy the warranty obligation. Also. but only when the consumer sale is made in the country to which distribution is authorized by us. • Failure of any parts caused by lack of cooling water. 10 . if they otherwise meet the terms of the limited warranty for that product. controls. launch. • Valve or valve seat grinding required because wear. • Haul-out. abnormal operation. Reasonable access must be provided to the product for warranty service. Customer must deliver product to an Authorized Dealer. telephone or rental charges of any type. or freezing temperatures. filters. • Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. towing charges. which results from starting power package out of water. and checking lubrication made in connection with normal services. Failures which are not related to the use of those parts or accessories. Should you have any questions concerning warranty coverage contact your authorized dealer. Warranty is limited to defects in material or workmanship. inconvenience or loss of time or income) are the owner’s responsibility. Maintenance and Warranty Manual. • Use of other than Quicksilver replacement parts when making warranty repairs. Installation errors. or adjusting belts. cleaning fuel injectors. and prior factory approval has been given to have the work performed at this facility). • Participating in or preparing for racing or other competitive activity.CD622 Warranty Coverage and Exclusion Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. • All incidental and/or consequential damages (storage charges. or where lead is thrown out of commutator because of excess cranking. improper installation or service. They will be pleased to answer any questions that you may have. lubricants or fluids changed as a matter of normal maintenance is customer’s responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration. lack of maintenance. • Oils. • Starter motors and/or armatures or field coil assembly. Refer to your Operation. including checking fuel injection pump timing. all related transportation charges and/or travel time. etc. condition responsible for noise should be corrected under the warranty. which are burned. removal and/or replacement of boat partitions or material because of boat design for necessary access to the product. • Labor performed by other than an Authorized Dealer may be covered only under following circumstances: When performed on emergency basis (providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out. • Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us. water in the starter motor. foreign material blocking inlets or power package being mounted too high. • Damage caused by neglect.

O. Outside the United States and Canada. 11 . Wl 54936-1939 • A new Owner Warranty Registration Card will be issued with the new owner’s name and address. or the closest distributor in your country. • There is no charge for this service. mail to: Attn: Warranty Registration Department Mercury Marine W6250 West Pioneer Road P. Registration records will be changed on the factory computer registration file.CE350 Transferable Warranty The product warranty is transferable to a subsequent purchaser. for the transferable warranty procedure that would apply to you. Box 1939 Fond du Lac. please contact the closest Mercury Marine Service Office. This will not apply to products used for commercial applications. In the United States and Canada. DIRECT SALE BY OWNER • The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. but only for the remainder of the unused portion of the limited warranty.

CD594 THIS PAGE IS INTENTIONALLY BLANK 12 .

CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. plus “common sense” operation. the equipment aboard and the safety of all occupants aboard. are major accident prevention measures. CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage. WARNING The operator (driver) is responsible for the correct and safe operation of the boat. Strict compliance with these special instructions while performing the service. Failure to comply could result in fire. be sure to read the Operation and Maintenance Manual for the accessory before operation. Observe them carefully. We strongly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used. WARNING Electrical system components on this engine are not external ignition protected. accompanied by the International HAZARD Symbol ! . If your MerCruiser unit is equipped with an accessory not manufactured by Mercury Marine. contact your dealer or the manufacturer of the accessory to secure the applicable manual. 13 . may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. explosion and/or severe personal injury. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES. UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). and on your power package WARNINGS and CAUTIONS. WARNING The use of accessories not manufactured or sold by Mercury Marine is not recommended for use with your MerCruiser unit. These “Safety Alerts” alone cannot eliminate the hazards that they signal.CD326 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION. We strongly recommend that other occupants be instructed on proper starting and operation procedures so they will be prepared should they be required to operate the power package and boat in an emergency. NOTICE Throughout this publication. IMPORTANT: Indicates information or instructions that are necessary for proper operation and/or maintenance. If you haven’t been supplied with such a manual. WARNING Hazards or unsafe practices which could result in severe personal injury or death.

sitting on elevated fishing boat decks. 14 . It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator’s position. Some remote control units are equipped with a lanyard stop switch. drinking alcohol or consuming drugs. or tie a knot in the lanyard. standing at planing speeds.CA619 General Information Lanyard Stop Switch 2 1 74608 The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. The lanyard is coiled to make its at-rest condition as short as possible so as to minimize the likelihood of lanyard entanglement with nearby objects. A lanyard stop switch can be installed on the dashboard or side adjacent to the operator’s position. operating at planing speeds in shallow or obstacle-infested waters. If it is desired to have a shorter lanyard. wrap the lanyard around the operator’s wrist or leg. and high-performance boats. Accidental ejections and falls overboard are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or gunwale at planing speeds. IMPORTANT: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator’s position to activate the switch. The lanyard is a cord usually between 4 and 5 feet (1220 and 1524 mm) in length when stretched out with an element on one end made to be inserted into the switch and a snap (2) on the other end for attaching to the operator. or daring. releasing your grip on a steering wheel that is pulling in one direction. Accidental ejections and falls overboard are more likely to occur in certain types of boats such as low sided sport boats or bass boats. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator’s position. high-speed boat maneuvers.

The boat operator should never leave the operator’s station without first disconnecting the stop switch lanyard from the operator. if the operator is accidentally ejected). 3 Loss of control when docking. WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e. However. 15 .g. 2 Loss of power and directional control in heavy seas. the boat will not complete a full circle. or all. This could cause any. a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut-down. of the following potentially hazardous situations: 1 Occupants could be thrown forward due to unexpected loss of forward motion – a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller. Accidental or unintended activation of the switch during normal operation is also a possibility. Always properly connect both ends of the stop switch lanyard to the stop switch and the operator.While activation of the lanyard stop switch will stop the engine immediately. While the boat is coasting. strong current or high winds. WARNING Should the operator fall out of the boat. it can cause injury to anyone in the boat’s path as seriously as the boat would when under power. the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately.

CA641 1 Courtesy of ABYC CA642 2A 2B 3A 3B Courtesy of ABYC 16 .

Although the occurrence is rare. 3 Examples of poor ventilation while boat is moving: A Running the boat with the trim angle of the bow too high. Carbon monoxide is a deadly gas that is odorless. include headache. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness. permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. swimmers and passengers in an unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide. colorless and tasteless. open side curtains. brain damage or death. as well as the generators that power various boat accessories. B Mooring close to another boat that has its engine running. or forward hatches to remove fumes. on a very calm day.CA620 Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards. Early symptoms of carbon monoxide poisoning. WARNING Avoid the combination of a running engine and poor ventilation. Install one or more carbon monoxide detectors in your boat. drowsiness. GOOD VENTILATION Ventilate passenger area. and nausea. CA643 POOR VENTILATION Under certain running and/or wind conditions. dizziness. 17 . B Running the boat with no forward hatches open (station wagon effect). sterndrives and inboard engines that propel boats. 2 Examples of poor ventilation while boat is stationary: A Running the engine when the boat is moored in a confined space. which should not be confused with seasickness or intoxication. 1 Example of desired air flow through the boat.

upon water contact it may penetrate under the water surface and “submarine” for an instant. If the bow of your boat pitches down far enough while airborne. Avoid wave or wake jumping whenever possible. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat. In such case the landing may cause the boat to violently veer in a new direction. get low and hang on to any boat hand hold. when this activity is done with speed to force the boat hull partially or completely out of the water. The primary concern is the boat changing direction while in the midst of the jump. Instruct all occupants that if a wake or wave jump occurs. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. There is another less common hazardous result from allowing your boat to launch off a wave or wake. However. certain hazards arise. WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. 18 . particularly when the boat re-enters the water.CE340 Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. The boat may also steer sharply to one side.

stop engine as soon as possible and inspect the drive system for any broken or loose parts. Operating with damaged underwater drive components. Under these conditions. Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts. rudder or the boat bottom. This will cause occupants to be thrown forward. Some of these situations could result in the following: • The boat could move suddenly in a new direction. rudder and/or boat. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles. do so at greatly reduced speeds. one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. transom fractures. 19 . even out of the boat. If damage is present or suspected. Striking a floating/underwater object may result in an infinite number of situations. water leaks. • A rapid reduction in speed. The boat should also be checked for any hull fractures. rudder or boat bottom could cause additional damage to other parts of the power package. WARNING Avoid serious injury or death from loss of boat control. Have the power package thoroughly inspected and any necessary repairs made. After striking a submerged object.CE336 Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components. the power package should be taken to an authorized dealer for a thorough inspection and necessary repair. • Impact damage to the underwater drive components. Keep in mind. or could affect control of the boat. boat speed should be kept to a minimum planing speed of 15 to 25 MPH (24 to 40 km/h). If continued running is necessary. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

flag and whistle or horn. • Check safety equipment on board. • Do not overload your boat. We strongly advise that everyone wear a life jacket at all times while in the boat. Instruct at least one person on board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. decks. Michigan Avenue Chicago. (3) Spare propeller. You should also review the NMMA Sources of Waterway Information booklet. Coast Guard Auxiliary. rockets or flares. unloading or are near the back (stern) of the boat. Courses are offered in the U.S. It lists regional sources of safety.A. paddle or oar. (3) The Red Cross and (4) your state or provincial boating law enforcement agency. • Perform safety checks and required maintenance. plus a throwable cushion or ring. Inquiries may be made to the Boating Hotline. Just shifting the drive unit into neutral is not sufficient. • Make sure everyone in the boat is properly seated. 1-800-368-5647 or the Boat U.S. Know your boat’s operating and loading limitations. thrust hubs and an appropriate wrench. fuses. • Passenger boarding. 20 . familiarize yourself with local and other governmental boating regulations and restrictions. (7) Spare operating equipment. (8) Transistor radio (9) Drinking water • Know signs of weather change and avoid foul weather and rough-sea boating. (6) Manual bilge pump and extra drain plugs.S. We strongly recommend that all powerboat operators attend one of these courses. bow.S. (5) Anchor and extra anchor line. cruising and local navigation and is available at no charge by writing to: Sources of Waterway Information National Marine Manufacturers Association 410 N. • Prepare other boat operators. Don’t allow anyone to sit or ride on any part of the boat that was not intended for such use. anywhere that sudden unexpected acceleration. transom. unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Boat operators should complete a boating safety course. When in doubt. (2) Signal devices: flashlight. • Know and obey all nautical rules and laws of the waterways. Here are suggestions of the types of safety equipment to carry when boating: (1) Approved fire extinguisher(s).S. and consider the following suggestions. batteries. raised fishing seats. This includes backs of seats. by (1) The U. Follow a regular schedule and ensure that all repairs are properly made. IL 60611 U. contact your dealer or the boats manufacturer. any rotating fishing seat. Coast Guard approved. (4) Tools for necessary minor repairs. sudden stopping. etc. wearable-type life jacket (personal flotation device). Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). water-proof storage containers. gunwales. compass and map or chart of area. first aid kit and book. • Use personal flotation devices.A. Foundation information number 1-800-336-BOAT. (2) The Power Squadron. Stop the engine whenever passengers are boarding. Federal Law requires that there be a U. bulbs. correctly sized and readily accessible for every person on board.CA476 Safe Boating Suggestions In order to safely enjoy the waterways. • Tell someone where you are going and when you expect to return.

there is sufficient force by the water on the propeller to cause the propeller to rotate. CA282 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. • Watch fallen skiers. load. or Mercury Marine. or any solid device rigidly attached to a moving boat or gear case. As an example. WHILE BOAT IS STATIONARY Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat. obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-849250--1) from your dealer. • Report accidents. • Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing). your boat traveling at 25 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front of you. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. This neutral propeller rotation can cause serious injury. • Know your boating area and avoid hazardous locations. Watch “the other guy. a moving gear case. A boating accident must be reported if (1) there is loss of life or probable loss of life. Seek further assistance from local law enforcement. (3) there is damage to boats or other property where the damage value exceeds $500.00 or (4) there is complete loss of the boat. WARNING Stop your engine immediately whenever anyone in the water is near your boat. They impair your judgment and greatly reduce your ability to react quickly. we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat. (2) there is personal injury requiring medical treatment beyond first aid. always keep a fallen or down skier on the operator’s side of the boat while returning to attend the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. or fishing seats should block the operators view when operating the boat above idle or planing transition speed.• Never be under the influence of alcohol or drugs while boating (it is the law). CC828 High-Speed And High-Performance Boat Operation If your boat is considered a high-speed or high-performance boat with which you are unfamiliar. No passengers. When using your boat for water skiing or similar activities. • Never drive your boat directly behind a water skier in case the skier falls. a moving boat. distributor. Serious injury to the person in the water is likely if contacted by a rotating propeller.” the water and your wake. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. 21 . For additional information.” The operator must have an unobstructed view particularly to the front. Whenever a boat is moving (coasting) and the drive unit is in neutral position.

the following conditions of the boat bottom should be observed. free of barnacles and marine growth. This growth must be removed before operation. • Improves rough water ride.CD3 Conditions Affecting Operation CD4 Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: A. • Increases danger of following wave splashing into boat when coming off plane. 22 . • Causes bow to bounce in choppy water. • At extremes. A. Shifting weight to front (bow) will: • Improves ease of planing on some boats. CA8 Bottom Of Boat To maintain maximum speed. it may clog water inlets and cause engine to over heat. C. fore and aft. Clean. Straight and smooth. can cause boat to porpoise. Free of distortion. can cause boat to veer back and forth (bow steer). nearly flat where it contacts the water. • At extremes. Shifting weight to rear (stern) will: • Generally increases speed and engine rpm. B. B. Marine vegetation may accumulate when boat is docked.

such as is needed for water skiing.2L LD D2. However. • Operating in a higher elevation causes an rpm loss (not as significant on D-Tronic models). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s). • Operating with a damaged propeller or dirty boat bottom causes an rpm loss. • Operating with increased load (additional passengers.CE352 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at the upper end of the specified throttle operating revolutions per minute (rpm) range.).6L D4. do not operate at full throttle when using the lower pitch propeller but not pulling skiers. the propeller must be changed to prevent loss of performance and possible engine damage.” IMPORTANT: The engines covered in this manual. depending upon the model. 23 .2L D-Tronic Engine Specified Operating Rpm Range 3600-3800 3400-3600 3400-3600 3600-3800 Rpm Governor or Limiter Setting (Begins At: ) 3830± 20 3630± 20 3650± 50 3875± 50 ± Select a propeller that will allow the engine power package to operate at or near the top of the recommended wide-open-throttle operating rpm range with a normal load. Specified engine wide-open-throttle (WOT) and operating rpm range are listed below and in “Specifications. use the next lower pitch propeller. as a significant loss in performance will result. etc. Be sure that propeller being used does not allow engine to run against the governor or limiter. there is a 100-150 rpm difference between 1 inch changes in propeller diameter or pitch. On the other hand. the following common problems may require that the propeller be changed to a lower pitch: • Warmer weather and greater humidity cause an rpm loss (not as significant on D-Tronic models). Engine rpm Limits MIE Model D3. operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage. For better acceleration.8L D-Tronic D4. are equipped with either a governor or a device that limits engine rpm. If full throttle operation is below the recommended range. Generally. pulling skiers. with a normal load aboard the boat.2L D4. After initial propeller selection.

in effect. Since air (containing oxygen) gets thinner as elevation increases. the basic problem still exists. enhances overall reliability and durability of the engine. dry day in spring and later. Heat and humidity thin the air. doesn’t have its old zip. it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum rpm range at wideopen-throttle with a normal boat load. can be somewhat regained by switching to a lower-pitch propeller that allows the engine to again run at recommended rpm. this propeller will. Nothing will regain this speed for the boater. sultry day in August. This. In some cases. but the coming of cool. Summer conditions of high temperature. in turn. on a hot. the engine operates at less than its recommended rpm. Humidity. Not only does this allow the engine to develop full power. do not compensate for increased loading or hull conditions. Generally. This condition can become particularly annoying when an engine is propped out on a cool. 24 . This. EDI engines however. In pointing out the practical consequences of weather effects. low barometric pressure and high humidity all combine to reduce the engine power. become too large. is reflected in decreased boat speeds. but equally important is the fact that the engine also will be operating in an rpm range that discourages damaging detonation.running on a hot. an engine -. For boaters to realize optimum engine performance under changing weather conditions. as much as 2 or 3 miles per hour in some cases.may encounter a loss of as much as 14% of the horsepower it would produce on a dry brisk spring or fall day.CD476 How Elevation and Climate Affect Performance NOTE: Engines equipped with EDI (D-Tronic engines) reduce the effects of changes in elevation and climate by automatically adjusting fuel flow for weather conditions and elevation. With the drop in available horsepower. however. elevation has a very noticeable effect on the wide-open-throttle power of an engine. the engine begins to starve for air. This will result in further loss of horsepower at the propeller with another decrease in boat speed. of course. Although some performance can be regained by dropping to a lower-pitch propeller. a gear-ratio change to more reduction is possible and very beneficial. barometric pressure and temperature do have a noticeable effect on the density of air. dry weather. Consequently. This secondary loss. humid summer day -.

or duty cycle. D4.CD5 Important Information CD598 Operation and Maintenance RECOMMENDED OPERATION / DUTY CYCLE It is the operator’s responsibility to operate within the following specified operational capability. • Continuous cruising rpm is limited to at or less than 90% of Wide-Open-Throttle rpm. or duty cycle. but are not limited to: search and rescue craft. Examples of Light Duty applications include.2L and D4. D2.8L D-Tronic. LIGHT DUTY RATING • Engine Specified Operating rpm Range Model D4. IMPORTANT: Damage caused by improper application or failure to operate within the operational capability.2L D-Tronic Rpm 3400-3600 3600-3800 • Wide-Open-Throttle operation is limited to less that 10% of operating time.8L D-Tronic. dive boats.6L. fast patrol boats. Light duty rating applies to planing boats where the use of full rated power at maximum rated rpm is limited (as stated above).2L LD D3. 25 .6L. as applicable to engine and installation: PLEASURE DUTY RATING • Engine Specified Operating rpm Range Model D4. Application to common commercial crafts having full-displacement or semi-displacement hulls exceeds the recommended operational capability. fire boats. NOTE: Pleasure duty rating applies to recreational planing craft used exclusively for pleasure and recreation. or duty cycle. and limited season fishing boats such as sport-fish charter boats.2L D-Tronic Rpm 3400-3600 3600-3800 • Wide-Open-Throttle operation is limited to short periods of time. • Annual operating time is not to exceed 500 hours. D2.2L LD D3. D4. will not be covered by the MerCruiser Diesel Limited Warranty.2L and D4.

and will keep your overall operating expenses at a minimum. and return the unit to an Authorized MerCruiser Dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such. • Prior to delivery. and resulting damages will not be covered by the limited warranty. and is factory set and sealed. See your Authorized MerCruiser Dealer for service aids. Removal of the seal and/or readjustment of the governed speed is considered misuse of engine. Proper maintenance and care of your power package will assure optimum performance and dependability. the injection pump lever Wide Open Throttle (WOT) Stop Screw adjusts the engine speed governor. • Familiarize the customer with the on-board equipment. the dealer should provide you with a copy of a Predelivery Inspection Checklist. ensure that all lubrication and maintenance instructions are complied with for safe operation. • Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory (branch or distributor) immediately upon sale of the new product. Readjusting the governed speed and operating above the specified rpm will cause extensive engine damage and/or failure. • At the time of delivery. • Explain and demonstrate the operation of the power package and boat. CA14 DEALER RESPONSIBILITIES In general. 26 . Individual operating habits and usage contribute to the need for maintenance service. • Make all necessary adjustments for maximum efficiency. a dealer’s responsibilities to the customer include predelivery inspection and preparation such as: • Make sure that the boat is properly equipped. CAUTION Except on the D-Tronic models.CD478 OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks. make certain that the MerCruiser power package and other equipment are in proper operating condition. are not considered defects in workmanship or material within the terms of the warranty.

CE8

Freezing Temperature And Cold Weather Operation
IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Refer to the following and to “Cold Weather or Extended Storage” for related information and draining instructions.

CAUTION
Seawater (raw water) section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use, if the possibility of freezing temperatures exist. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. In order to operate the engine in temperatures of 32° F (0° C) or lower, observe the following instructions:

• At the end of each daily operation, COMPLETELY drain seawater section of cooling system to protect against
damage by freezing.

• At the end of each daily operation, drain water from water separator, if equipped. Fill fuel tank at end of daily
operation to prevent condensation.

• Use required permanent-type antifreeze solution to protect components against damage by freezing. • Be sure to use proper cold weather lubrication oil, and be sure the crankcase contains a sufficient amount. • Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment
is in optimum condition.

• At temperatures of –4° F (–20° C) and below, it is recommended that you use a coolant heater to improve
cold starting.

• If operating in arctic temperatures of –20° F (–29° C) or lower, consult your dealer for information about special cold weather equipment and precautions.
CA20

Launching and Boat Operation Care

CAUTION
During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat may enter the water rapidly and at a steep angle. This may force water through the exhaust system into the cylinders. The more weight on the transom, the more likely this is to occur. Slowing down rapidly, stopping suddenly or backing up rapidly may cause a following wave to “swamp” the transom causing water to enter the cylinders through the exhaust system causing severe engine damage. When backing up rapidly, the same situation may occur as stated in the preceding paragraph. In any of these situations, water entering the engine could cause severe damage to internal parts. Refer to “Attention Required After Submersion,” in this “Operation, Maintenance and Warranty Manual.”
CA408

Drain Plug and Bilge Pump
The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug and/or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the MerCruiser Limited Warranty.

27

CA409

Attention Required After Submersion
• Before recovery, contact an Authorized MerCruiser Dealer. • After recovery, immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage
to power package.
CA21

Stolen Power Package
If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.
CE9

Replacement Service Parts
Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both fresh and saltwater environments. These conditions require numerous special parts. Care should be exercised when replacing marine engine parts, as specifications are quite different from those of the standard automotive engine. Since marine engines must be capable of running at or near maximum rpm much of the time, special pistons, camshafts and other heavy-duty moving parts are required for long life and peak performance. These are but a few of the many special modifications that are required in MerCruiser marine engines to provide long life and dependable performance.
CA772

Do-It-Yourself Maintenance Suggestions
If you are one of those persons who likes to do-it-yourself, here are some suggestions for you.

• Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of
machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. • Do not attempt any repairs which are not covered in this manual unless you are aware of the precautions (“Cautions” and “Warnings”) and procedures required. Your safety is of our concern. • If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don’t understand. Do not attempt repairs if you do not understand the procedures.

• There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs
unless you have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would charge you. • Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer’s mechanic must reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem. • Do not telephone the dealer, service office or the factory to attempt for them to diagnose a problem or request the repair procedure. It is difficult for them to diagnose a problem over the telephone. • Your Authorized Dealer is there to service your power package. They have qualified factory-trained mechanics. It is recommended you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble-free boating pleasure.

28

CE385

Diagnosing EDI Problems
Your Authorized Mercury MerCruiser Dealer has the proper service tools for diagnosing problems on Electronic Diesel Injection (EDI) Systems. The Electronic Control Module (ECM) on these engines have the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM’s memory. This code can then be read later by a service technician using a special diagnostic tool.
CE335

Multiple EDI Engine Battery Precautions
SITUATION Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charging current. EDI Electronic Control Module (ECM): The ECM requires a stable voltage source. During multiple engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine’s battery. The voltage may go below the ECM’s minimum required voltage. Also, the alternator on the other engine may now start charging. This could cause a voltage spike in the engine’s electrical system. In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine just appears to have an ignition miss. RECOMMENDATIONS Batteries: Boats with multi-engine EDI power packages require each engine be connected to its own battery. This ensures that the engine’s Electronic Control Module (ECM) has a stable voltage source. Battery Switches: Battery switches should always be positioned so each engine is running off its own battery. DO NOT operate engines with switches in BOTH or ALL position. In an emergency, another engine’s battery can be used to start an engine with a dead battery. Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. Isolators should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose. Generators: The generator’s battery should be considered in the same manner as another engine’s battery.

29

• AVOID full throttle acceleration from stopped position. To do this. repeat starting procedure. to avoid overheating the starter motor.6L. It is normal for oil consumption to be somewhat high during the break-in period. Allow engine to idle until it has reached normal operating temperature.2L.2L D-Tronic Engines: Proceed to Step 2. 30 . which greatly reduces the likelihood of problems. if an abnormal reading occurs. 2800 rpm and 3400 rpm. This break-in procedure allows the proper seating of the pistons and rings. do not engage starter motor for more than 15 seconds each time. Run engine in gear for 3 minutes at each of the following rpms: 1800 rpm. • OBSERVE INSTRUMENTS. then. Run engine in gear for 3 minutes at each of the following rpms: 1500 rpm. Run engine in gear for 3 minutes at each of the following rpms: 1200 rpm. • FREQUENTLY CHECK crankcase oil and transmission fluid levels. • AT END OF 20-HOUR break-in period. During this process the engine will not run because no fuel is injected. 2400 rpm and 3000 rpm. the following rules must be observed: • DO NOT operate engine below 1500 rpm for extended periods during the first 10 hours. • DO NOT exceed 75% of full throttle during the first 10 hours except during engine Initial Break-In Procedure.2L LD Engines Only: Pre-lubricate the turbocharger and engine. hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds. During the next 10 hours. This will rotate the starter motor and engine/oil pump. b. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. 2. To avoid overheating the starter motor. During this period. On D2. If engine does not start. Follow instructions “a” or “b”: a. D4. stop engine immediately and determine cause. IMPORTANT: Never operate the starter motor longer than 15 seconds at a time. 3000 rpm and Maximum Rated Full-Throttle rpm. On D3. • DO NOT operate at full throttle until engine reaches normal operating temperature. Refer to appropriate “Starting. 3. and D4.8L D-Tronic and D4. During this break-in period. shift into gear as soon as possible after starting engine and advance throttle so that rpm is above 1500 (provided that conditions permit safe operation at this speed). 4. occasional operation at full throttle (5 minutes at a time maximum) is permissible. • DO NOT operate at any one constant speed for extended periods.CD625 Engine Break-In INITIAL BREAK-IN PROCEDURE It is especially important that the following procedure be used on new diesel engines. CE11 20 HOUR BREAK-IN PERIOD IMPORTANT: The first 20 hours of operation is the engine break-in period. wait 1 minute to allow the starter motor to cool. 5. Allow the starter motor to cool down for one minute and repeat the above described process. IMPORTANT: It is recommended that the boat not be accelerated hard until this procedure has been completed. Shifting and Stopping” section and start engine. 1. Fill crankcase with correct grade and viscosity oil. remove break in oil and replace oil filter. Add if necessary.

the following recommendations should be considered. you should contact your dealer at the end of the first 100 hours of operation.CA211 After Break-In Period To help extend the life of your MerCruiser power package. as evidence of compliance therewith. for cylinder head retorque service. but no later than 150 hours. Refrain from prolonged operation at maximum (full throttle) rpm. • Operation at 3/4 throttle setting or lower is recommended. CE299 100 Hour Checkup It is a condition for the continuation of warranty. If you are in an area where the product is operated continuously (year-round operation). or once yearly. an Authorized MerCruiser Dealer should be contacted to discuss and/or perform various scheduled maintenance items. by the product owner. that the product be taken to an authorized Mercury MerCruiser service dealer after the first 100 hours of operation. A copy of the dealer service work order must be kept. • Use a propeller that allows the engine to operate at or near the top of the maximum rpm range (See “Specifications” section) when at full throttle with a normal boat load. CA414 End of First Season Checkup At the end of the first season of operation. whichever occurs first. 31 .

CE230 1 71856 3 71856 2 71856 5 4 72753 73546 71856 7A 73547 6 71772 8 7B 73547 32 .

2L D-Tronic . D4. automatic preheating (if equipped) and all instruments are operational.The engine is stopped when the key switch is turned to the OFF position. The green area on the gauge is the normal operating range.2L. The instrumentation shown is required for safe operation of boat and engine. Then. while the Key Switch is in the RUN position. and D4. Refer to “Specifications” for normal operating readings.6L. all electrical circuits.indicates battery voltage. indicator lamps. 3 Coolant Temperature Gauge . 8 Engine Stop Switch . all electrical circuits are off and engine cannot be started.8L D-Tronic and D4.CE21 Operation CE355 Quicksilver Instruments and Instrumentation Shown is the basic Quicksilver instrumentation and engine system monitor display for the Diesel Power Package. NOTE: Refer to manufacturer’s instructions and explanations about instrumentation. key switch can be turned to the OFF position. A D3. 1 Oil Pressure Gauge . In the OFF position. The engine can only be stopped by using the Engine Stop Switch.indicates engine speed (rpm). In the START position the engine can be started.indicates engine oil pressure. and D4. No electrical circuit is operational when the key switch is turned to the OFF position. 5 Voltmeter. if equipped with other than Quicksilver instrumentation. Gauges and engine system monitor panel may be individually mounted. 33 .D3.If engine is running the key switch cannot be used to stop engine.Horn sounds if: (1) Cooling system temperature too high (2) Oil pressure is too low (3) Transmission fluid temperature is excessive 7 Key Switch . 4 Cruise Log (Engine Hour Meter) . 6 Audio Warning Horn Standard Features . Refer to “Specifications” for normal operating readings.2L LD . NOTE: Key can only be removed in the OFF position.is used to stop the engine. D4.has three positions. Operator should become familiar with all instrumentation before operating the engines. or collectively mounted in the optional single panel available from Quicksilver. Stop Switch is toggled DOWN and held until engine stops completely.2L LD . This is done by electrically shutting off fuel delivery system.2L. B D2.indicates engine coolant temperature. In the RUN position.records engine running time. and if alternator and charging circuit are functioning properly. 2 Tachometer .6L.

34 . The timed preheat period begins when the key switch is turned on. the engine can be started only after the light goes out.2L models. NOTE: The audio warning horns are wired in a parallel circuit. D Coolant Temperature Warning Lamp . the fuse will burn out. When engine starts.located in-line on key switch power supply wire and protects the Instrumentation and wiring should an electrical overload occur. if equipped.The appropriate light functions as follows: A Preheat Indicator Lamp .8L D-Tronic and D4. install new fuse and check systems to function.indicates a problem with charging system if lamp illuminates while engine is running. and then.CD491 n E D C B A 1 2 CE353 3 71891 71722 71891 1 Engine System Monitor Features . are preheating the combustion chambers. B Charge Indicator Lamp . or transmission fluid temperature is too high (See the following note). After cause is corrected. light should go off. If a horn sounds while engine is running. E Malfunction Indicator Lamp (MIL) D2. The light stays on until the preheat period is complete.2L D-Tronic Only .lights up when the glow plugs. The cause should be determined and corrected. only when the engine is cold.has three positions.indicates excessive engine coolant temperature if lamp illuminates while engine is running. C Oil Pressure Warning Lamp . IMPORTANT: Cause for overload must be determined and corrected before attempting to install new fuse or fuse failure will occur again. When the switch is toggled DOWN the audio warning horn will sound allowing the operator to perform a test of the audio warning horn. in the normal position all electrical circuits operate in a standard fashion (as described above). 2 Panel Lights/Audio Test Switch .6L and D4.indicates low engine oil pressure if lamp illuminates while engine is running. Check “blown” (burned) fuse if key is turned to RUN or START and nothing happens. On D3.additional lamp indicates when a problem exists that requires service if lamp illuminates while engine is running. If an overload occurs. Lamp will light when key switch is ON and engine is not running. check coolant temperature and coolant level or this may be an indication of excessive transmission temperature. With switch toggled UP the instrumentation lights are all illuminated. 3 20 Amp Fuse and Holder .

2 When equipped with Quicksilver instrumentation and wiring a 20 amp fuse and holder is located in-line on key switch power supply wire and protects the Instrumentation and wiring should an electrical overload occur. Further checks must be made on electrical system. 1 Two 60 amp circuit breakers provide protection for engine wiring harness and instrumentation power lead. If breaker remains open. 35 . when engine must be operated and cause for high current draw cannot be located and corrected. electrical overload has not been eliminated. IMPORTANT: The cause must be found and corrected before replacing fuse or resetting circuit breaker. turn OFF or disconnect all accessories connected to engine and instrumentation wiring. a fuse will blow or a circuit breaker will trip open. Reset by pushing RESET button IN (on outside). If an overload occurs. In an emergency.CE354 2 73546 1 75301 CE289 Electrical System Overload Protection If an electrical overload occurs. Reset circuit breaker. the fuse will burn out. Check “blown” (burned) fuse if key is turned to RUN or START and instruments do not work and/or if switches do not function.

CE143 1 5 2 3 4 73866 9 7 6 8 70537 71339 36 .

Do not thread screw all the way out. all controls may not have all features shown. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. NOTE: If boat is equipped with a remote control other than shown. Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Refer to “Lanyard Stop Switch” at the front of this manual for safety warning on the use of this switch.allows engine rpm to be increased or decreased.adjusts control handle friction so motor speed can be set and driver does not have to hold handle. CE158 Remote Controls (Two Lever) Your boat may be equipped with one of many Quicksilver remote controls available. Move lever forward to shift to FORWARD gear. 3 Lanyard Stop Switch . 6 Shift Lever . Adjust to tension desired.Allows engine throttle advancement without shifting the engine. 8 Friction Screw . Do not thread screw all the way out. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position. turn screw counterclockwise. Turn screw clockwise to increase tension and counterclockwise to decrease tension. consult your dealer for a description and/or demonstration of the control. 1 Neutral Lock Bar .Turns ignition OFF whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. to decrease. Lever in full vertical position shifts to NEUTRAL. Also. and should only be used to assist in starting the engine. CAUTION Never shift unit into or out of gear unless throttle lever is at idle rpm. Continue pushing back to increase speed. Continue pushing forward to increase speed.controls the effort needed to move control handle out of NEUTRAL. This is done by disengaging the shift mechanism from the control handle.CE386 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. Move lever backward to shift to REVERSE gear.Prevents accidental shift and throttle engagement. all controls may not have all features shown.This screw can be adjusted to increase or decrease the tension on the control handle. 7 Throttle Lever . IMPORTANT: Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control.Operation of the shift and throttle are controlled by the movement of the control handle. NOTE: If boat is equipped with a remote control other than shown. Pull the control handle back from “Neutral” with a quick firm motion to the first detent for REVERSE gear. 2 Throttle Only Button . 4 Control Handle Tension Adjustment Screw . 9 Detent Screw . turn screw clockwise. Turn screw clockwise to increase friction.shifts unit into gear with full lever movement. This will help prevent “Creep” of the remote control handle. consult your dealer for a description and/or demonstration of the control. Neutral lock bar must be pulled UP to move the control handle out of neutral. To increase tension. 5 Control Handle . Also. 37 .

CC200 3 2 1 3 2 1 38 .

Continue pushing back to increase speed. Also. 3 Control Handle(s) . and should only be used to assist in starting the engine. 1 Throttle Only Button . NOTE: If boat is equipped with a remote control other than shown. all controls may not have all features shown. The throttle only button can be depressed only when the remote control handle is in the NEUTRAL position. This is done by disengaging the shift mechanism from the control handle. Continue pushing forward to increase speed. consult your dealer for a description and/or demonstration of the control. Push the control handle forward from NEUTRAL with a quick firm motion to the first detent for FORWARD gear. All controls feature an integral safety switch that allows starting engine in NEUTRAL only.CE159 Remote Controls (Console Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. Pull the control handle back from NEUTRAL with a quick firm motion to the first detent for REVERSE gear. This will help prevent “Creep” of the remote control handle.This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed to adjust). 39 . 2 Control Handle Tension Adjustment Screw .Allows engine throttle advancement without shifting the engine.Operation of the the shift and throttle are controlled by the movement of the control handle. Adjust to tension desired. Turn screw clockwise to increase tension and counterclockwise to decrease tension.

CD599 2B 2A 1A 71386 1B 76378 3 40 .

• Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature.2L LD.2L. • Never operate the starter motor longer than 15 seconds at a time.2L models. and D4.2L Models. or specified in your boat owner’s manual. wait 1 minute to allow the starter motor to cool. If engine does not start.2L LD NOTE: Does not include engines equipped with D-Tronic fuel injection. and D4.D3.Crankcase Oil. 41 .2L LD models. • Check the air cleaner for proper installation of filter element. Propane. It is used to manually shut off engine by cutting off the fuel supply. D4. This is done using an electric solenoid and a coolant temperature switch circuit. such as Ether. Refer to “Table Of Contents. This is done by moving lever in direction shown. or Gasoline in the engine air intake system. Refer to “Specifications . 1 Cold Start Assist: A On D3. B On D4. to avoid overheating the starter motor.6L and D4.2L.CD628 Starting. then.6L. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant. Lever should be reset as soon as engine starts and idles smoothly. repeat starting procedure. as indicated by your dealer. a Cold Start Device located on the injection pump is used to aid in starting when the temperature is below 50° F (10° C).6L. 3 Check all items listed in the Maintenance Schedules and Operation Chart . a Cold Start Lever located on the injection pump is used to aid in starting when the temperature is below 50° F (10° C). the following steps must be observed before starting: • Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage). D4. It can be engaged by moving the lever in the direction shown. Shifting and Stopping . WARNING Do not use volatile starting aids.” • Be sure that all electrical connections are secure.D3. BEFORE STARTING THE ENGINE IMPORTANT: As an added precaution.located on the injection pump of all engines except D-Tronic Engines. A On D3.6L and D4.” 4 Perform any other necessary checks. Lever will reset as soon as engine coolant reaches a prescribed temperature. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage. B On D4.2L LD Models. 2 Mechanical Engine Stop Lever .

The warm-up period provides time for the lubricating oil to establish a film between moving parts. 42 . It is very important that any engine be warmed up before applying full load. During this process the engine will not run because no fuel is injected. Stop the engine if oil pressure is not within this range. reset Cold Start Lever when engine idles smoothly.6L and D4. 4 If engine has not been run for a period of time and will not readily start with the standard starting procedure. NOTE: Engine warm-up time during cold weather can be reduced by operating vessel at reduced engine speed. the indicator lamp will cease to be lighted and the engine can be started. 3 After a lengthy layup (several months or more) pre-lubricate the turbocharger and engine. 5 Turn key switch to the RUN position. oil pressure should be within range listed in the engine specifications chart. Refer to Maintenance Chart. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. 1 Turn on and run engine compartment bilge blower (if equipped) for five minutes.CD629 STARTING COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. Commence normal vessel operation when systems reach operating temperatures. Move knob up and down four or five strokes. CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine. Locate and correct the problem. When cylinder temperature is great enough to sustain combustion. 10 After the engine has reached operating temperature. set Cold Start Lever if temperature is below 50° F (10° C). Check to ensure charge indicator and oil pressure warning lamps go out. 8 Check to ensure all instrumentation is functioning properly and indicating normal readings. Proceed to next step after a slight increase in oil pressure is observed. To avoid overheating the starter motor. 2 On D3. check to ensure all instrumentation is functioning properly. open engine hatch to air out bilge before attempting to start engine(s). Allow the starter motor to cool down for one minute and repeat the above described process.6L and D4. Run engine at idle rpm until engine temperature is within normal operating range. there is a hand pump/primer knob located on the fuel filter header. Or. Damage to drive unit could occur. 6 Turn key switch to START position and release when engine fires. hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds. 7 Run engine at Idle rpm until engine temperature is within normal operating range. CE31 ENGINE WARM UP CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine.2L only. This will rotate the starter motor and engine/oil pump. Observe indicator lamp for glow plugs. 9 After starting. do not engage starter motor for more than 15 seconds each time. To do this. CAUTION Never attempt to shift unit unless engine is at idle rpm.2L only. NOTE: On D3.

CD341 ENGINE SHUT-DOWN (STOPPING) 5 Place remote control lever in NEUTRAL. CAUTION Avoid damaging the turbocharger and engine. quick motion forward to shift to FORWARD gear. Move control/shift lever with a firm. Check to ensure charge indicator and oil pressure warning lamps go out. After shifting drive unit. or Wide Open Throttle. refer to the following procedure: 3 Push and pull repeatedly on remote control handle until handle returns to the neutral detent position. advance throttle to desired setting. 2 Once underway. Immediate engine shutdown (stopping) after high load operation may result in permanent turbocharger bearing damage. 43 .CD340 STARTING WARM ENGINE 1 Turn on and run engine compartment bilge blower for five minutes (if equipped). 2 Turn key switch to the RUN position. open engine hatch to air out bilge before attempting to start engine(s). 4 After handle returns to the neutral detent position.resume normal starting procedures. 8 Turn key switch to the OFF position. until engine stops completely. or backward to shift to REVERSE. be sure remote control/throttle lever is in NEUTRAL. engine oil pressure should be within the range listed in the engine specifications chart at maximum rpm. 3 Turn key switch to START position and release when engine fires. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. Damage to drive unit could occur. If engine does stop with drive unit in gear. CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine. Operate the engine at IDLE for several minutes before shut-down. CB575 IMPORTANT: Avoid stopping engine if the drive unit is in gear. 4 Check to ensure all instrumentation is functioning properly and indicating normal readings. 6 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool. 7 Toggle STOP switch DOWN and hold. This may take several tries if the power package was operating above idle rpm when the engine stopped. CE33 SHIFTING CAUTION Never attempt to shift unit unless engine is at idle rpm. Locate and correct the problem. Or. 1 To shift unit. Stop the engine if oil pressure is not within this range.

Air out bilge completely. Prime fuel injection system. if equipped. and D4. etc. fluid. AFTER STARTING Observe all gauges and warning lights to check condition of engine. after the indicator lamp for glow plugs (if equipped) ceases. Turn battery switch OFF. Flush seawater cooling circuit. if equipped. If not normal.2L. for five minutes. equipped. fluid. if necessary. if equipped.6L. Check that charge indicator and oil pressure indicator lamps cease AFTER engine starts. Open fuel shut-off valve. Turn key switch to OFF position. if necessary. and exhaust leaks. Open seacock. Turn key switch to RUN and check that lights and indicator lamps come on. if equipped. if operating in saltwater area. Check shift and throttle control operation. Warm-up engine at idle rpm for several minutes. STOPPING & SHUT DOWN Shift remote control lever to neutral position. Toggle STOP switch Down and hold. Release key when engine starts. Check for leaks . D4. Close fuel shut-off valve. stop engine.D3. etc. oil. if Run engine at idle speed several minutes to allow the turbocharger and engine to cool. water. 44 . Turn key switch to START. Pre-lubricate turbocharger and engine. WHILE UNDERWAY Frequently observe all gauges and indicator lights to monitor engine condition. water. if equipped.CD630 Operation Chart . Turn on and run engine compartment bilge blower. oil. Check steering operation.fuel. Check for fuel. until engine completely stops. Turn battery switch ON. if Check that mechanical engine-stop lever is not engaged.2L LD STARTING PROCEDURE Open engine hatch. equipped. Close seacock.

8L D-Tronic and D4. as indicated by your dealer. or Gasoline in the engine air intake system.Crankcase Oil. the following steps must be observed before starting: • Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage). Refer to “Table Of Contents. Shifting and Stopping . • Be sure engine crankcase is filled to correct level with the proper grade of oil for the prevailing temperature. • Check the air cleaner for proper installation of filter element. CAUTION It is good practice to ventilate the engine compartment prior to servicing any engine components to remove any fuel vapors which may cause difficulty breathing or be an irritant.2L D-Tronic WARNING Do not use volatile starting aids. then. to avoid overheating the starter motor.2L D-Tronic.CD631 75301 1 CE297 Starting. Refer to “Specifications . or specified in your boat owner’s manual. Propane.D2.” 2 Perform any other necessary checks. If engine does not start. wait 1 minute to allow the starter motor to cool.8L D-Tronic and D4. • Never operate the starter motor longer than 15 seconds at a time.D2. 1 Check all items listed in the Maintenance Schedules and Operation Chart . such as Ether.” • Be sure that all electrical connections are secure. repeat starting procedure. Explosion hazard resulting from ignition of vapors by glow plugs could cause severe personal injury and engine damage. 45 . BEFORE STARTING THE ENGINE IMPORTANT: As an added precaution.

46 . open engine hatch to air out bilge before attempting to start engine(s). for five minutes. It is very important that any engine be warmed up before applying full load. Or. Attempt to start engine following normal procedure. oil pressure should exceed 10 psi (69 kPa) minimum. NOTE: Engine warm-up time during cold weather can be reduced by operating vessel at reduced engine speed. 4 Turn key switch to START position. Check to ensure charge indicator and oil pressure warning lamps go out. Shut the engine down if oil pressure does not register on the gauge within 20 to 30 seconds after start. 2 After the engine has reached operating temperature. If the oil pressure does not meet these minimum limits. CE31 ENGINE WARM UP CAUTION Improper or no warm-up of engine can seriously impair the Iife of your diesel engine. there is a hand pump/primer knob located on the fuel filter header. 5 Check to ensure all instrumentation is functioning properly and indicating normal readings. 2 If engine has not been run for a period of time and will not readily start with the standard starting procedure.CE298 STARTING COLD ENGINE IMPORTANT: Always check all fluid levels before starting engine. 1 After starting. stop the engine. the indicator lamp will cease to be lighted and the engine can be started. The warm-up period provides time for the lubricating oil to establish a film between moving parts. Locate and correct the problem. Stop the engine if oil pressure is not within this range. 3 Turn key switch to the RUN position. Refer to Maintenance Chart. oil pressure should be within range listed in the engine specifications chart. Move knob up and down four or five strokes. if equipped. When cylinder temperature is great enough to sustain combustion. locate and correct the problem. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. 1 Turn on and run engine compartment bilge blower. Run engine at idle rpm until engine temperature is within normal operating range. check to ensure all instrumentation is functioning properly. Within seconds after starting the engine. Release key when engine starts and allow switch to return to RUN position. Commence normal vessel operation when systems reach operating temperatures. if equipped. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. CAUTION Do not increase the engine speed until the oil pressure gauge indicates normal. Observe indicator lamp for glow plugs.

Locate and correct the problem. CD366 ENGINE SHUT-DOWN (STOPPING) 9 Place remote control lever in NEUTRAL.CE32 STARTING WARM ENGINE 1 Turn on and run engine compartment bilge blower for five minutes (if so equipped). be sure remote control/throttle lever is in NEUTRAL. quick motion forward to shift to FORWARD gear. After shifting drive unit. Stop the engine if oil pressure is not within this range. 47 . or Wide Open Throttle. 6 Once underway. 8 After handle returns to the neutral detent position. 2 Turn key switch to the RUN position. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. Or. Check to ensure charge indicator and oil pressure warning lamps go out.resume normal starting procedures. Move control/shift lever with a firm. Check to ensure glow plug preheat lamp is not illuminated. Stop the engine if oil pressure is not within this range. This may take several tries if the power package was operating above idle rpm when the engine stopped. refer to the following procedure: 7 Push and pull repeatedly on remote control handle until handle returns to the neutral detent position. 5 To shift unit. Oil pressure should be within the range listed in the engine specifications chart. CAUTION Avoid damaging the turbocharger and engine. Locate and correct the problem. 10 Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool. Operate the engine at IDLE for several minutes before shut-down. CB575 IMPORTANT: Avoid stopping engine if the drive unit is in gear. 11 Turn key switch to the OFF position. engine oil pressure should be within the range listed in the engine specifications chart at maximum rpm. or see your Authorized MerCruiser Dealer if you are unable to determine the problem. If engine does stop with drive unit in gear. advance throttle to desired setting. CE33 SHIFTING CAUTION Never attempt to shift unit unless engine is at idle rpm. 3 Turn key switch to the START position and release when engine fires. Immediate engine shutdown (stopping) after high load operation may resulting in permanent turbocharger bearing damage. Damage to drive unit could occur. or backward to shift to REVERSE. 4 Check to ensure all instrumentation is functioning properly and indicating normal readings. open engine hatch to air out bilge before attempting to start engine(s).

Air out bilge completely. ceases. Check steering operation. if equipped. Turn key switch to OFF position. Warm-up engine at idle rpm for several minutes. if necessary. water. Turn on and run engine compartment bilge blower. Open seacock. fluid. oil. Check that charge indicator and oil pressure indicator lamps cease AFTER engine starts. Close fuel shutoff valve. Release key when engine starts. Close seacock. if equipped. fluid. and exhaust leaks. Turn battery switch ON. if operating in saltwater area. after the indicator lamp for glow plugs.D2. if Prime fuel injection system. if equipped. to OFF. equipped. Turn key switch to START. water.2L D-Tronic STARTING PROCEDURE Open engine hatch.CD346 Operation Chart . STOPPING & SHUT DOWN Shift remote control lever to neutral position. stop engine. if equipped. if equipped. oil. equipped.8L D-Tronic and D4. If not normal. for five minutes. Check for fuel. Open fuel shutoff valve. WHILE UNDERWAY Frequently observe all gauges and indicator lights to monitor engine condition.fuel. if equipped. etc. if Run engine at idle speed several minutes to allow the turbocharger and engine to cool. etc. Turn battery switch. Check for leaks . Flush seawater cooling circuit. Check shift and throttle control operation. Turn key switch to RUN and check that lights and indicator lamps come on. 48 . AFTER STARTING Observe all gauges and warning lights to check condition of engine.

Seacock should be installed in an area where it is easily accessible and supported adequately to prevent hose fatigue. A 1-1/2 in. CE14 Seawater Strainer Seawater Strainer should be provided. containing special additives. as this will promote rusting of internal surfaces. Strainer should be installed in water inlet hose after seacock to allow operator to shut off water inlet when cleaning strainer. Do not drain closed cooled section for storage. A minimum flow rate of 40 gallons (150 litres) per minute is required. (38mm) brass ball or gate valve is minimum required. The coolant. Refer to the coolant manufacturer’s instructions. If engine will be exposed to freezing temperatures.CE13 Specifications CD11 Seacock Seacock (water inlet valve) used. or no. This gelatin will block engine and heat exchanger passages causing engine overheating. must have an internal cross-sectional area equal to or greater than hose to prevent restricting water flow. In addition. silicate formula of ethylene glycol antifreeze in solution with deionized water. the closed cooling system and engine. and overheating of the engine. and deionized. IMPORTANT: The anti-freeze/coolant used in these marine engines must be a low (or no) silicate ethylene glycol. Description Quicksilver Premixed Marine Engine Coolant Fleetguard Complete Part Number 92-813054A2 Obtain Locally 49 . and be of sufficient size to ensure that an adequate supply of water will be maintained for cooling engine. Some acceptable types of anti-freeze/coolants are listed in the following table. The closed cooling section should be kept filled year-round with an acceptable anti/freeze/coolant solution. purified water. water. Using other types of engine coolant may cause fouling of the heat exchangers. to protect engine and closed cooling system to lowest temperature to which they will be exposed. Common tap water or softened water contains unwanted minerals which can leave large deposits in the system that restrict the cooling system efficiency. This can only be assured by using the proper anti-freeze. make sure that closed cooled section is filled with a properly mixed antifreeze/coolant solution. Because diesel engines are high compression engines and related higher engine operating temperatures are created. Do not combine different types of coolants without knowing that they are compatible. It is recommended that the closed cooled section of the cooling system be filled with a low. if not premixed. should be mixed before being added to the closed cooling system using a proper anti-freeze together with deionized water. additives and inhibitors. CD535 Anti-Freeze/Coolant CAUTION Alcohol or Methanol base antifreeze or plain water are not recommended for use in closed cooling section of cooling system at any time. A low silicate formula prevents antifreeze separation which causes a silicate gelatin to form. additives and inhibitors introduced into acceptable coolant solutions will form a protective film on internal passages and provide protection against internal cooling system erosion. including related cooling passages must remain as clean as possible to provide adequate engine cooling. Refer to “Maintenance Schedules” for respective change intervals. Strainer should be installed in an area where it will be easily accessible for inspection and cleaning.

NOTE: If your engine suddenly becomes noisy after a fuel fill. This mixture of gasoline.50% by weight. Failure to comply could result in fire. and excessive wear of internal engine parts. Any sign of leakage or deterioration requires replacement before further engine operation. and having a minimum cetane rating of 45. high sulphur content diesel fuel will greatly increase: • Corrosion on metal parts. IMPORTANT: Use of improper or water contaminated diesel fuel can damage your engine seriously. A lower cetane number could cause hard starting and slower warm-up. Increasing the cetane number will not improve overall engine performance. • Deterioration of elastomer and plastic parts. gasohol and/or alcohol be mixed with diesel fuel for any reason. meeting ASTM Standards D975 (or fuel rated Diesel DIN 51601). you possibly received substandard fuel with a low cetane rating. and fuel filters should be inspected for leakage. The Cetane number is a measure of the ignition quality of diesel fuel. particularly after storage. Grade 2-D diesel fuel is required. metal or fiberglass. Use of improper fuel is considered misuse of engine. particularly bearings. but it may be necessary to raise the cetane rating for low temperature. • Starting and operating difficulties. 50 . WARNING FIRE HAZARD: Fuel leakage from any part of the fuel system can be a fire hazard which can cause serious bodily injury or death. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES. fuel lines. hardening. swelling or corrosion. Limits may vary in countries outside of the United States.CD164 Fuel Requirements WARNING Electrical system components on this engine are not external ignition protected. UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (REF: 33 CFR). On intermittent use engines. WARNING Under no circumstances should gasoline. Careful periodic inspection of entire fuel system is mandatory. whether plastic. gasohol and/or alcohol with diesel fuel is highly flammable and produces a significant risk to the user. All fuel components including fuel tanks. or high altitude use. and damage caused thereby will not be covered by warranty. Sulphur content of the above fuel is rated at 0. explosion and/or severe personal injury. primers. soften. fittings. maximum (ASTM). and could increase engine noise and exhaust emissions. • Corrosion and extensive damage.

2L. The following oils are approved by Mercury Marine and Marine Power Europe. Virtually all diesel fuels are “climatized” to allow their use in the particular region for that time of the year. CD632 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection.CE16 Diesel Fuel In Cold Weather Unaltered diesel fuels thicken and “gel” in cold temperatures. the engine requires engine oil with a rating of HD-SAE-API SH. a specially blended 25W-40 SH. CF/CF-2 oil with Marine Additives. CF/CF-2.6L ENGINES AGIP SIGMA TURBO ARAL OL P 327 AUTOL VALVE-SHP AVIATICON TURBO BP VANELLUS C3 EXTRA CALTEX RPM DELO 450 OIL CASTROL TURBOMAX CENTURY SHPD CHEVRON DELO 450 MOTOR OIL MULTIGRADE DEUSOL TURBOMAX DIVINOL MULTIMAX EXTRA DUKCHAMS HYPERGRADE ECUBSOL OIL CD PLUS ELF MULTIPERFORMANCE ESSO HESSOL TURBODIESEL FANAL INDOL X FINA KAPP LDO FUCHS TITAN TRUCK 1540 GULF SUPERFLEET SPECIAL IP TAURUS M MOBIL DELVAC 1400 SUPER TOTAL RUBIA TIR VALVOLINE SUPER HD LD 51 . for all temperature operations. For all temperature operation use 15W-40 oil. unless treated. D4.2L D-TRONIC ENGINES AGIP SIGMA TURBO SHELL MYRINA MOPAR MOBIL DELVAC 1400 SUPER TEXACO URSA SUPER TD WINTERSHALL MULTI-REKORD TOTAL RUBIA TIR VEEDOL TURBOBOSTAR WINTERSHALL VIVA 1 RECOMMENDED OILS FOR D3. If it becomes necessary to further treat diesel fuel. following that product’s directions. RECOMMENDED OILS FOR D4. We strongly recommend the use of QUICKSILVER 4-Cycle Marine Engine Oil.8L D-TRONIC AND D4.2L LD. D2. it is the owner/operator’s responsibility to add a commercial “standard brand” “anti-gel” diesel fuel additive.

in.7 kW 1 at temp.2L Specification . 65A 750 cca.Propeller Selection” for additional information.185° F ( 80° . ( 90mm ) 22:1 Propeller Shaft Horsepower (Kilowatts) In-Line 6 Cylinder Diesel 1-5-3-6-2-4 4300 ± 50 3830 ± 20 3800 700 4200 ± 50 3630 ± 20 3600 750 rpm 3600 .6v.Intake / Exhaust Maximum Pressure Difference Between Cylinders Maximum High Idle No Load rpm Governed rpm Setting (Begins At:) Rated rpm At Wide Open Throttle 2 Idle rpm in Forward Gear Oil Pressure: Oil Temperature Water: ( 2 Total ) 1 at temp.6 l ) 3. ( 3. ( 4. : Power rated in accordance with NMMA Procedure .2.230° F ( 100° . ( 100mm ) 21. 52 . ( 94mm ) 3.937 in.ISO 3046 (Technically Identical to ICOMIA 28-83).5 .2 l ) 3.6L AND D4.5:1 Hydraulic 72 psi ( 500 kPa ) 180 (134) 175 (130) 219 cu. ( 92mm ) 3. 2. Refer to “Conditions Affecting Operation .3800 rpm 22-36 psi [ 1.110° C ) 160° F ( 70° C ) 180° F ( 82° C ) 203° F ( 95° C ) 176° . or 180 Ah 12v.Inboard (MIE) D3.4 bar ( 345-400 kPa ) ] 212° .5 .6L 1 1 Description Crankshaft Horsepower (Kilowatts) Engine Type Displacement Firing Order Bore Stroke Compression Ratio Valve Clearance . 14.2L 220 (164) 210 (157) 254 cu.700 in. : Thermostats: Oil: ( 1 Total ) Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter 1 2 D4.5 bar ( 152-248 kPa ) ] 50-58 psi [ 3.543 in. in.CE356 Engine Specifications D3.85° C ) 12-volt Negative ( – ) Ground 949W.622 in. 950 mca.

3. ( 100mm ) 16. ( 2.Propeller Selection” for additional information.185° F ( 80° .Inboard (MIE) D2.2 l ) 1-5-3-6-2-4 Propeller Shaft Horsepower (Kilowatts) Engine Type Displacement Firing Order Bore Stroke Compression Ratio Valve Clearance . 2.8L D-TRONIC AND D4.8 l ) 1-3-4-2 D4.937 in. or 180 Ah 12v. ( 4. 65A 750 cca. : 22-45 psi [ 1.5:1 Hydraulic 72 psi ( 500 kPa ) 4200 ± 50 3850 ± 50 3800 700 750 rpm 3800 rpm Water: ( 2 Total ) 1 at temp. in.1 bar ( 152-310 kPa ) ] 50-80 psi [ 3.Intake / Exhaust 3. 14.6v.ISO 3046 (Technically Identical to ICOMIA 28-83).2L D-Tronic 250 (186) 240 (179) In-Line 6 Cylinder Diesel 254 cu.8L D-Tronic 165 (123) 160 (119) In-Line 4 Cylinder Diesel 169 cu.7 kW 1 at temp. ( 94mm ) 3.110° C ) 160° F ( 70° C ) 180° F ( 82° C ) 203° F ( 95° C ) 176° . : Oil: ( 1 Total ) 2 Maximum Pressure Difference Between Cylinders Maximum High Idle No Load rpm Governed rpm Setting (Begins At:) Rated rpm at Wide Open Throttle Low Idle rpm Oil Pressure: Oil Temperature Thermostats: Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter 1 2 Power rated in accordance with NMMA Procedure . Refer to “Conditions Affecting Operation . 950 mca.5 .5.5 .85° C ) 12-volt Negative ( – ) Ground 949W.CE357 D2. in.700 in.2L D-TRONIC Description Crankshaft Horsepower (Kilowatts) 1 1 Specification .6 bar ( 345-556 kPa ) ] 212° .230° F ( 100° . 53 .

( 94 mm ) 3.6v. 70A 750 cca. Maximum High Idle No Load rpm Governed rpm Setting (Begins At:) Rated rpm at Wide Open Throttle Idle rpm in Forward Gear 600 rpm Oil Pressure: 3600 rpm Oil Temperature Water: ( 2 Total ) 1 at temp. 2.700 in.3 . 54 .Inboard (MIE) D4.2L LD 200 (149) 1 Description Crankshaft Horsepower (Kilowatts) 1 Propeller Shaft Horsepower (Kilowatts) Engine Type Displacement Firing Order Bore Stroke Compression Ratio Valve Clearance .5 .4 bar ( 345-400 kPa ) ] 212° . 14. or 180 Ah 12v. ( 4. in.1. : Thermostats: Coolant Temperature Electrical System Alternator Rating Recommended Battery Rating Starter 1 2 1 at temp.2L LD Specification . : Oil: ( 1 Total ) Power rated in accordance with NMMA Procedure .7 kW Maximum Pressure Difference Between Cyl.937 in.85° C ) 12-volt Negative ( – ) Ground 980W.2 l ) 1-5-3-6-2-4 3. ( 100 mm ) 16.110° C ) 160° F ( 70° C ) 180° F ( 82° C ) 203° F ( 95° C ) 176° .ISO 3046 (Technically Identical to ICOMIA 28-83).185° F ( 80° .5 bar ( 130-149 kPa ) ] 50-58 psi [ 3.5:1 Hydraulic 72 psi ( 500 kPa ) 4000 ± 50 3650 ± 50 3600 600 19-22 psi [ 1.CE358 D4.Intake / Exhaust 194 (145) In-Line 6 Cylinder Diesel 254 cu.230° F ( 100° . 950 mca.

Model Total Oil Capacity Oil Drainage Closed Cooling Circuit 1 D3. Make And Model Hurth 630A 630V 450A Specification 1 3-1/4 (3) 4-1/2 (4) 4-1/2 (4) Dexron III Automatic Transmission Fluid Fluid Type 1 Always use dipstick to determine exact quantity of oil required 55 .S.2L D-Tronic and D4. NOTICE Unit Of Measurement: U.2L LD 12-3/4 ( 12 ) 10-3/4 ( 10 ) 1 1(1) 1(1) 13-3/4 ( 13 ) Always use dipstick to determine exact quantity of oil required CE359 TRANSMISSIONS IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines). Quarts (Liters). Quarts (Liters).S.CD671 Fluid Capacities ENGINES NOTICE Unit Of Measurement: U.2L 12-3/4 ( 12 ) 10-3/4 ( 10 ) 1 13-3/4 ( 13 ) Always use dipstick to determine exact quantity of oil required Model Total Oil Capacity Oil Drainage Closed Cooling Circuit 1 D2. All capacities are approximate fluid measures.6L 10-1/2 ( 10 ) Oil Pan Oil Filter Oil Cooler 12-3/4 ( 12 ) 8-1/2 ( 8 ) 1(1) 1(1) D4.8L D-Tronic 8-1/2 ( 10 ) Oil Pan Oil Filter Oil Cooler 11-2/3 ( 11 ) 6-1/2 ( 8 ) D4. All capacities are approximate fluid measures.

See the decal on engine for identification. Add fluid at dipstick hole. This eliminates the engine wiring as a potential source of ignition.” 56 . 5 Closed Cooling System Coolant . CF/CF-2 required. WARNING Always disconnect battery cables from battery BEFORE working on fuel system to prevent fire.SAE 30W motor oil. and Quicksilver Corrosion Guard. while others should be performed by an Authorized Mercury MerCruiser Dealer.use only recommended engine coolant. Before attempting maintenance or repair procedures not covered in this manual. 3 All Exterior Surfaces .CD10 Maintenance CE102 5 2 4 1 2 4 3 71893 CE365 General Information WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. Refer to “Specifications” for list of approved oils. Some listings can be done by owner/operator. NOTE: Maintenance points are color coded for ease of identification. 2 All pivot points . as needed. 4 Crankcase Oil .Dexron III automatic transmission fluid (ATF). IMPORTANT: Refer to MAINTENANCE SCHEDULES for complete listing of all routine and scheduled maintenance to be performed. it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly. CE360 Maintenance Aids 1 Hurth Transmissions .Quicksilver Primer and Spray Paint. Refer to “Engine Coolant.API rating of SH.

flush cooling system after each use.CE361 Maintenance Schedules Routine Maintenance * Each Day Start Check crankcase oil (interval can be extended based on experience). Check coolant level. Operating in Saltwater Only: treat engine surface with corrosion guard. If operating in salt. Clean air filter every 50 hours of operation. brackish or polluted waters. * Only perform maintenance which applies to your particular power package D D D D D D D D Each Day End Weekly Every Two Months 57 . Check battery connections and fluid level. Check water strainer and clean. Check water pickups for debris or marine growth. Drain any water from fuel filter after each use (if operating in freezing temperatures). Check transmission fluid.

Inspect condition and tension of belts. Change crankcase oil and filter. Lubricate cables and linkages. Change transmission fluid. missing or damaged parts. Replace fuel filter(s). Retorque cylinder head bolts. damaged or corroded fasteners.Maintenance Schedules (Continued) Scheduled Maintenance After After First First 20 100 hours hours Change crankcase oil and filter. Touch-up paint power package and spray with corrosion guard. z Whichever Occurs First D D D D D D D D D D Every Every Every 200 500 100 Every hours hours Annuhours or 2 or 3 or 5 ally Annually years years years z z z Every 1000 hours Per or 5 OEM years z 58 . Check electrical system for loose. Check steering system and remote control for loose. Retorque engine mounts.

Maintenance Schedules (Continued) Scheduled Maintenance(Continued) After After First First 20 100 hours hours Check cooling system and exhaust system hose clamps for tightness. z Whichever Occurs First D D D D Every Every Every 200 500 100 Every hours hours Annuhours or 2 or 3 or 5 ally Annually years years years z z z D Every 1000 hours Per or 5 OEM years z D D D 59 . Disassemble and inspect seawater pump and replace worn components. Inspect both systems for damage or leaks. Clean fuel tank. Clean. Check anodes on diesel models. Replace coolant. inspect and test pressure cap. Check engine-to-propeller shaft alignment. Replace air filter. Clean aftercooler core. Clean seawater section of closed cooling system.

CE362 2 71380 1 71382 3A 73322 3B 75301 3C 76394 4 B A 6 60 27661 .

7 Start engine and run at 1500 rpm for two minutes to fill all hydraulic circuits. engine must be run at 1500 rpm for two minutes immediately prior to checking level. stop engine and allow 5 minutes for oil to drain into pan. MAX mark on dipstick. do not overfill. A D3.top line.twist and pull to remove. as some of the fluid from transmission fluid cooler and hoses may have drained back into transmission. to bring level up to maximum mark on dipstick. 5 Remove dipstick. Add automatic transmission fluid. Fill to this level. contact your Authorized Mercury MerCruiser Dealer. if necessary. add transmission fluid to bring level up to maximum mark on dipstick. IMPORTANT: To accurately check fluid level.2L B D2. Stop the engine completely before removing or inserting dipstick. add oil as follows. IMPORTANT: Be sure to push dipstick all the way down into dipstick tube when checking fluid level. Oil must be between MIN and MAX marks on dipstick.2L LD CE363 TRANSMISSION FLUID Hurth Hydraulic Transmission 4 Push dipstick handle down and seat fully before checking fluid level. Wipe clean and reinstall into dipstick tube. Add specified oil to bring level up to. 6 If low. Check fluid level as indicated on dipstick.do not allow fluid level to drop below this line.CD639 Checking Fluid Levels CRANKCASE OIL CAUTION Avoid possible injury or damage to oil dipstick and internal engine components. but not over. B MINIMUM Fluid Level . 9 Reinstall dipstick.6L and D4.8L D-Tronic and D4. 1 Remove dipstick. Dipstick has neoprene seal . If necessary. Fluid level may be somewhat over maximum mark. 10 If transmission fluid level was extremely low. If it becomes necessary to check oil level during operation. A MAXIMUM Fluid Level . 2 Remove dipstick and observe oil level. Reinstall oil filler cap. Do not remove crankcase oil dipstick when engine is running.2L D-Tronic C D4. 3 Remove oil filler cap. 8 Stop engine and quickly check fluid level. 61 .

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2 If coolant level in coolant recovery bottle was low: • Inspect coolant recovery system for leaks. • Inspect coolant tank cap gaskets for damage and replace if necessary. • Also. To have cap tested. check coolant level in coolant recovery bottle. If coolant is low. Coolant level must be to the bottom edge of the tank filler neck. contact your Authorized MerCruiser Dealer. Adding cold coolant to a hot engine may crack the cylinder head or crankcase. you should allow engine to cool and then slowly and carefully remove coolant tank cap. Refer to “Specifications” for proper coolant. Refer to items 1 and 2 above. the tank cap maintains pressure on the coolant tank. Never use water alone. add coolant slowly. let the engine cool for approximately 15 minutes before adding coolant. Coolant level must be between the “ADD” and “FULL” marks (on front of bottle). to ensure that coolant recovery system is functioning properly. remove fill cap from coolant recovery bottle and add specified coolant as required. with the engine running. add specified coolant as necessary to bring up to proper level. WARNING Do not remove coolant tank cap when engine is hot. CAUTION If the coolant should get extremely low and the engine very hot. causing severe burns. If level is low. Coolant may discharge violently.CD166 ENGINE COOLANT 1 Before starting engine. 3 Periodically. 63 . then. It may not be holding pressure properly.

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D2. Coat sealing ring on new filter with oil and install filter.8L D-Tronic and D4.6L and D4. D4.2L D-Tronic D Oil drain hose .CE366 Changing Fluids Refer to “Maintenance Schedules” for lubricant change interval. Use only recommended motor oil. Stop the engine completely before removing or inserting dipstick. do not use a filter wrench.2L D-TRONIC IMPORTANT: Change oil when engine is warm from operation.2L D-Tronic IMPORTANT: When refilling engine with oil always use dipstick to determine how much oil is required. 6 Remove and discard oil filter and sealing ring.D2. Hand tighten only. IMPORTANT: On D3. or damage to oil dipstick and internal engine components.6L and D4.6L. Refer to “Specifications”. pre-lubricate turbocharger and engine.2L C Fitting . Coolant in closed cooling system should be changed at specified intervals by your Authorized Mercury MerCruiser Dealer. Doing this TOGETHER turns the engine without starting it. 3 Remove fitting from end of crankcase oil drain hose laying on top of engine. Lubricant should be changed before placing boat in storage. carrying away more impurities.D3. CRANKCASE OIL AND FILTER . D2. A Fitting .2L B Oil drain hose .6L and D4.8L D-Tronic and D4. A D3.2L D-Tronic 4 Install crankcase oil pump onto threaded fitting of oil drain hose. 7 Remove oil fill cap and refill engine with new oil. When crankcase is empty. 65 . remove pump and reinstall crankcase oil drain hose fitting. CAUTION Avoid possible injury. To do this.2L B D2. Watch that starter does not overheat. DO NOT engage starter for more than 15 seconds. A Crankcase oil pump (Quicksilver Part Number 90265A2) B Threaded Fitting 5 Pump oil out of crankcase into drain pan. allow at least one minute cool down time before re-engaging starter for another 15 seconds.D3. move the STOP switch toggle lever DOWN and hold in this position while you turn the key switch to START position. 1 Start engine and allow it to warm up to normal operating temperature. 2 Stop engine and allow some time for oil to drain into oil pan (approximately 5 minutes). Tighten securely.2L. Warm oil flows more freely. Do not remove crankcase oil dipstick when engine is running.6L and D4.2L Engines only: After oil change. Refer to “Specifications” for quantity and grade of oil.8L D-TRONIC AND D4.8L D-Tronic and D4.D3.

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IMPORTANT: When refilling engine with oil always use dipstick to determine how much oil is required. do not use a filter wrench.AND D4.2L LD IMPORTANT: Change oil when engine is warm from operation. Refer to “Specifications” for quantity and grade of oil. 67 . remove hose and reinstall crankcase oil pump fitting. 5 Remove and discard oil filter and sealing ring. 1 2 3 4 Start engine and allow it to warm up to normal operating temperature. Watch that starter does not overheat. Doing this TOGETHER turns the engine without starting it. allow at least one minute cool down time before re-engaging starter for another 15 seconds. Do not remove crankcase oil dipstick when engine is running.CD644 CRANKCASE OIL AND FILTER . To do this. move the STOP switch toggle lever DOWN and hold in this position while you turn the key switch to START position. Hand tighten only. CAUTION Avoid possible injury. Tighten securely. Refer to “Specifications”. Use only recommended motor oil. pre-lubricate turbocharger and engine. Warm oil flows more freely. Stop the engine completely before removing or inserting dipstick. Coat sealing ring on new filter with oil and install filter. Pump oil out of crankcase into drain pan. Remove fitting from end of crankcase oil pump. or damage to oil dipstick and internal engine components. carrying away more impurities. IMPORTANT: After oil change. 6 Remove oil fill cap and refill engine with new oil. Attach a suitable hose for draining. When crankcase is empty. DO NOT engage starter for more than 15 seconds. Stop engine and allow some time for oil to drain into oil pan (approximately 5 minutes).

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2 Remove fluid filter from housing by turning (counterclockwise) and pulling at the same time.Fluid Capacities”. then turn T-handle clockwise until tight. Refer to “Specifications . 8 Push down until cover is fully seated (top of cover flush with housing).CE368 Transmission Fluid DRAINING 1 Clean the exterior of transmission near fluid filter. 9 Start engine and run for two minutes to fill system with fluid. 7 Coat O-rings on filter cover with transmission fluid. 10 Stop engine and quickly check fluid level. and max. Fluid should be between min. Reinstall drain plug and tighten securely. lines on dipstick. 4 Hurth V-Drive Models: Remove drain plug from transmission and allow fluid to drain. CAUTION Transmission fluid filter and cover must be properly seated to avoid fluid foaming and/or loss of fluid resulting in decreased efficiency and/or damage to transmission. 69 . Replace if necessary: A Filter Element B Cover C O-rings 6 Fill transmission to proper level. FILLING IMPORTANT: Use only recommended Automatic Transmission Fluid (ATF). Pump fluid from housing. 5 Remove filter element from cover and inspect O-rings for wear. 3 Hurth Down-Angle Models: Push hose of suction pump through suction pipe and down to the bottom of the housing. through fluid filter cavity.

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at point shown. CE370 Drive Belts . Belt should move no more than 3/16 in. IMPORTANT: To prevent unfiltered air from entering the engine be certain that all of the air intake screen is covered by the foam element when installed. (5 mm) either way. Allow element to completely dry before use and install around air intake screen. Use element clean and dry for proper filtration.CD648 Air Filter Cleaning / Replacement 1 Disconnect crankcase vent hose from end of air cleaner. Do not clean foam element in petroleum based solvents or cleaners. preferably as a “matched pair. or damage to polyester foam element. ALTERNATOR DRIVE BELT AND ENGINE WATER CIRCULATING PUMP BELT. 71 . Refer to “Maintenance Schedules” for replacement interval under normal conditions. with moderate hand pressure. with moderate hand pressure. OR BELTS 2 Inspect drive belt. If any drive belts need replacement or tension needs adjustment. or glazed surfaces). IMPORTANT: No treatment (such as partial oil saturation) is required or recommended on air cleaner foam element prior to use. at point shown. Except D3.All Engines. 5 Check belt tension by depressing upper strand of belt. IMPORTANT: On models with dual-row pulleys and dual belts always inspect both belts. A Crankcase Vent Hose B Foam Element C Intake Screen Housing CAUTION Avoid potential fire hazards and injury. fraying. cracks. Always replace both belts as a pair.” WARNING Make sure engine is shut off and ignition key is removed before inspecting belts. (5 mm) either way.6L Engines All drive belts must be periodically inspected for tension and condition (excessive wear. 3 Check belt tension by depressing upper strand of belt. see your Authorized Mercury MerCruiser Dealer. Replace the foam element if it is deteriorated or torn. Never renew just one of the two belts driving the alternator and engine water circulating pump. Belt should move no more than 3/16 in. Wash foam element in warm water and detergent until clean. for excessive wear or damage. or belts. VACUUM PUMP BELT (IF EQUIPPED) 4 Inspect drive belt for excessive wear or damage. Carefully remove air cleaner foam element from around air intake screen housing mounted on turbocharger inlet.

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Torque mounting and tensioning screws to 15 lb-ft (21 Nm). Loosen mounting bolt.D3. Belt should depress 3/16 inch (5 mm).CE372 Drive Belts . 11 Install new vacuum pump belt and adjust tension. if equipped. Loosen nut and tensioning bolt. Pivot alternator until belt can be removed. 1 All drive belts must be periodically inspected for tension and condition (excessive wear. A Alternator Belt/Water Circulating Pump Belt B Vacuum Pump Belt (If equipped) 2 Check belt tension by depressing belt. Tighten hose clamps securely. with moderate hand pressure. if equipped. VACUUM PUMP BELT (IF EQUIPPED) 9 Loosen the vacuum pump mounting and tensioning screws. 73 . ALTERNATOR DRIVE BELT AND ENGINE WATER CIRCULATING PUMP BELT CAUTION Avoid water entering boat. behind the bracket. Remove seawater hoses at seawater pump. seacock (if so equipped) must be closed. retighten all fasteners securely. Remove old belt and install new belt. Mounting bolt Tensioning bolt 8 Open seacock. fraying. When tension is correct. or plug seawater inlet hose. at points shown. cracks.6L Engines WARNING Make sure engine is shut off and ignition key is removed before inspecting belts. If seawater pump hoses are to be removed with boat in the water. Adjust belt tension by pivoting alternator. 10 Appropriately pry or move the vacuum pump to loosen belt. or remove plug from seawater inlet hose and reconnect hose. Remove old belt. Remove power steering belt. or water inlet hose must be disconnected and plugged to prevent water from flowing into boat. or glazed surfaces). Tighten hose clamps securely. 7 Reconnect seawater hoses to seawater pump. 3 4 5 A B 6 Close seacock.

6L.2L LD 74 .8L D-Tronic and D4.2L D-Tronic B D3.2L. A D2.CE373 1 71374 2A 75332 2B 76405 CE374 Lubrication SHIFT CABLE 1 Lubricate pivot points with SAE 30W motor oil. and D4. CD674 THROTTLE CABLE 2 Lubricate pivot points with SAE 30W motor oil. D4.

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6L and D4. B D2.2L Models. ensure that bleed screw on fuel filter bracket is closed.2L LD Models. A D3.2L LD Only: Loosen. move plunger on hand pump/primer up and down repeatedly. and D4. move the plunger (upper portion) up and down as needed. Filter is full when this occurs. D4.8L D-Tronic.2L Models. To operate the hand pump/primer.8L D-Tronic. Fill fuel system up to the point that fuel filter is full following previous procedure (Filling Fuel Filter). as an accumulation of rust. Unless specified otherwise. B D2. until an air-free stream of fuel flows from injection pump bleed screw. D4. 5 On D3.2L Models. 77 . (2) refill fuel filter when changing filter.CE406 Fuel System CAUTION Absolute cleanliness is required for work on the fuel system. FUEL TANK CLEANING AND FLUSHING IMPORTANT: Diesel fuel should not be left in tank during winter storage.6L and D4. or (3) to prime the fuel system if engine has not been run for a while. sludge and wax residue will form. Move the hand pump/primer plunger up and down several times as previously outlined. B D2. 1 Refer to boat manufacturer’s instructions and clean fuel tank at specified intervals.2L D-Tronic and D4.2L LD Models.2L D-Tronic and D4. CD657 FILLING (BLEEDING) FUEL SYSTEM NOTE: Follow this procedure if fuel system was run dry or if part of fuel system was drained for a service function. D4. Tighten bleed screw.2L D-Tronic and D4. 4 Loosen bleed screw on fuel filter bracket. D4.6L and D4.2L. bleed screw on fuel injection pump (located between fuel line connection fittings on injection pump). A D3. As previously outlined.8L D-Tronic. then. flush and clean diesel fuel tank every 1000 hours or 5 years. CD655 PRIMING FUEL SYSTEM 3 Prime engine if it has not been run for a while or if engine will not start. fuel injection components have very close tolerances.2L LD Models. until an air free stream of fuel flows from bleed screw. DO NOT REMOVE.6L. A D3. whichever occurs first. CD656 FILLING FUEL FILTER NOTE: Follow this procedure after installing new filter or if fuel has been drained from filter checking for water. Continue to repeatedly move plunger on hand pump/primer. Attempt to start engine. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system. Tighten bleed screw. CD654 HAND PUMP/PRIMER 2 A plunger-type of hand pump/primer is located on the fuel filter bracket and is used to: (1) refill fuel system if system was run dry.

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Tighten securely. Do not allow sources of open flame in the area. in warm weather open the water bleed valve before starting daily operations. Be sure ignition key is OFF. fire retardant container. where there is a possibility that the condensed water will freeze. Open by turning the drain “b” counterclockwise (as viewed from the bottom of the filter). B D2. Fill fuel filter as previously outlined.2L Models.6L and D4. Drain until fuel is clear in appearance. 79 . A D3. D4. drain the filter shortly after the end of daily operations. Wipe up any spilled fuel immediately. in an appropriate air tight. NOTE: To ensure complete draining.2L D-Tronic and D4. Dispose of fuel soaked rags.2L LD Models. Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death. paper. 1 The filter “a” can be drained of water and small dirt particles by opening drain cock at bottom of filter. Close drain by turning clockwise.8L D-Tronic.CD659 DRAINING WATER SEPARATING FUEL FILTER WARNING Be careful when draining water separating fuel filter. Diesel fuel is flammable. Do not allow fuel to contact any hot surfaces which may cause it to ignite. etc. In cold weather.

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C Coat sealing ring on new filter with clean motor oil. Check filter and drain cap for fuel leaks. Do not allow fuel to contact any hot surfaces which may cause it to ignite. E Check that bottom drain cap is securely tightened.2L. etc. Fuel soaked items may spontaneously ignite and result in a fire hazard which could cause serious bodily injury or death. Do no tallow sources of open flame in the area. If leaks exist.CD661 REPLACING WATER SEPARATING FUEL FILTER CAUTION Any water entering the fuel injection system will disable the system. Check for water in water separating fuel filter before startup. 2 On D4. Dispose of fuel soaked rags. Diesel fuel is flammable. D4. CAUTION If water should enter the fuel injection system. C Thread filter onto bracket and tighten securely by hand. 1 On D3. in an appropriate air tight. Install on new filter. stop engine immediately and contact your Authorized Mercury MerCruiser Dealer. paper. Fill fuel filter as explained previously. Remove water separating fuel filter and sealing ring from mounting bracket.2L LD Models: A Remove and discard water separating fuel filter and sealing ring from mounting bracket. daily. Check filter connection for fuel leaks.6L. WARNING Make sure no leaks exist before closing engine hatch. Do not use a filter wrench. take unit to an Authorized MerCruiser Dealer IMMEDIATELY. fire retardant container. Do not use a filter wrench. D Align filter to bracket. WARNING Be careful when changing water separating fuel filter. B Remove the drain cap and O-ring from bottom of the existing filter. so that corrosion and rusting of the injectors and other components can be avoided. D2. Be sure ignition key is OFF. Do not use a filter wrench. Twist locking ring by hand to secure filter to bracket. Wipe up any spilled fuel immediately.8L D-Tronic and D4. Check filter and drain cap for fuel leaks.2L D-Tronic Models: A Twist locking ring by hand. Fill fuel filter as explained previously. B Coat sealing ring on new filter with clean motor oil. 81 . D Check that bottom drain cap is securely tightened. If leaks continue. recheck filter installation. 3 All Models: Start and run engine.

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Remove strainer. and clean any debris from strainer housing. A B C D E F Screws and Washers Cover Strainer Drain Plug and Washer Housing Gasket CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized Mercury MerCruiser Dealer. Check gasket . Remove screws and washers. If boat is not equipped with a seacock.CE376 Cleaning Quicksilver Seawater Strainer NOTE: Refer to manufacturers instructions if equipped with other than a Quicksilver seawater strainer. Prior to starting engine. remove and plug seawater inlet hose to prevent a siphoning action that may occur. Reattach cover with screws and washers. drain plug and washer. or remove plug from seawater inlet hose and reconnect. open seacock if so equipped. close seacock. After starting engine. check for leaks. Reinstall drain plug and washer. allowing seawater to flow from the drain holes or removed hoses. or remove and plug seawater inlet hose.replace when necessary (if it leaks). Tighten hose clamps securely. and cover. and/or air in system (which would indicate an external leak). 2 Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range). CAUTION When cleaning seawater strainer. 1 With engine off. if so equipped. close seacock if so equipped. flush both strainer and housing with clean water. 83 .

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idle speed position and start engine. Operate engine at idle speed. be certain the area around propeller is clear. causing engine to overheat. for about 10 minutes. or until discharge water is clear. Refer to “Maintenance Schedules. Using appropriate flushing adaptor. Suction created by seawater pickup pump may collapse flushing hose. remove propeller. 3 The closed cooling section of cooling system that contains coolant does not need to be flushed. if equipped. seacock. As a precautionary measure. CAUTION Watch temperature gauge on dash to ensure that engine does not overheat.” 85 . CAUTION If boat is in the water. to prevent contaminated water from flowing back into cooling system. or disconnect and plug seawater inlet hose. or is to remain in the water. To avoid possible injury. if so equipped. water inlet hose must be disconnected and plugged to prevent contaminated water from flowing into cooling system and/or boat. in NEUTRAL. Tighten hose clamp securely. Shut off water. 2 Place remote control in NEUTRAL. must be closed until engine is to be restarted. remove and plug seawater inlet hose to prevent a siphoning action that may occur. 1 Close seacock. attach a tag to the ignition switch warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine. if equipped.CE377 Flushing Seawater Cooling System To prevent silt and/or salt buildup in the seawater circuit of cooling system. CAUTION When flushing seawater cooling system. WARNING When flushing. Partially open water tap (about 1/2 maximum). and no one is standing nearby. CAUTION Do not run engine above 1500 rpm when flushing. Stop engine. Coolant is changed at specified intervals. Disconnect water inlet hose from seawater pickup pump connection. allowing seawater to flow from the drain holes or removed hoses. remove flushing adaptor from seawater pump inlet hose connection and reconnect water inlet hose. flush with freshwater at specified Intervals. connect water hose between adaptor and water tap. If boat is not fitted with a seacock. If boat is not equipped with a seacock. close seacock.

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Battery electrolyte is a corrosive acid and should be handled with care. the following conditions regarding the boat bottom should be observed: Clean. 87 . and may form an explosive atmosphere around the battery for several hours after it has been charged. or when specific gravity drops below battery manufacturer’s specifications. Free of distortion. which serves as a sacrificial anodes. free of barnacles and marine growth.In some areas it may be advisable to paint bottom of boat to help prevent marine growth. Straight and smooth fore and aft. lf electrolyte is spilled or splashed on any part of the body. WARNING Do not use jumper cables and a booster battery to start engine. WARNING Batteries contain acid which can cause severe burns . (19mm) B Diameter When New . immediately flush the exposed area with liberal amounts of water and obtain medical aid as soon as possible. Refer to specific instructions and warnings accompanying your battery. sparks or flames.5/8 in. check at least once yearly. If this information is not available.Avoid contact with skin. Hydrogen gases that escape from the battery during charging are explosive. See your dealer for recommendations for your boat.3/4 in.CD119 Corrosion And Corrosion Protection INTERNAL COMPONENTS 1 There are anodes as part of the intercooler and heat exchanger systems. 2 Replace when eroded more than 50%. When charging batteries. (15mm) CA103 Miscellaneous Maintenance BATTERY 3 All lead acid batteries discharge when not in use. nearly flat where it contacts water. A Length When New . This explosive gas escapes fill/vent cell caps. sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury. Recharge every 30 to 45 days. CE281 BOTTOM OF BOAT 4 • • • To maintain maximum speed. Do not recharge a weak battery in the boat. Remove battery and recharge in a ventilated area away from fuel vapors. CC72 ANTIFOULING PAINTS 5 Antifouling Paint . is well-vented. Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte. be sure area where batteries are located. observe the following precautions when handling a battery. eyes and clothing Batteries also produce hydrogen and oxygen gasses when being charged.

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before starting engine a source of water must be supplied to water intake (inlet) openings. IMPORTANT: If boat has already been removed from water. as pump impeller may be damaged and subsequent overheating damage to engine or drive unit may result. 1 Start engine and run until it reaches normal operating temperature. CAUTION The engine must be prepared for long storage periods to prevent internal corrosion and severe damage. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine. Stop engine.CD44 Cold Weather Or Extended Storage CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. They are in the closed cooling circuit. Start engine and run for about 15 minutes. CAUTION DO NOT operate engine without water flowing thru seawater pickup pump. Change oil and filter. Follow all warnings and flushing attachment procedures stated in “Flushing Cooling System”. WARNING Do not remove coolant cap when engine is hot . 2 Do not open either of these two petcocks. Check for oil leaks. IMPORTANT: Drain seawater section of closed cooling system only. IMPORTANT: Closed cooling section must be kept filled year-round with the specified coolant. NOTE: Refer to the following pages for continuation of specific draining instructions. 89 .coolant may discharge violently. CD280 Power Package Layup IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer.

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Lower hose and drain completely. must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system. seacock. if so equipped. Sponge-out or soak-up any water that remains in the bottom part of each section. Reconnect hoses. 6 Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. if so equipped. Remove all water from heat exchanger sections. Install and torque the end covers “b” on the upper heat exchanger section to 120-132 lb-in. Torque the end covers “a” on the lower heat exchanger section to 108-120 lb-in. or disconnect and plug seawater inlet hose. 3 Disconnect seawater outlet hose at aft end of power steering cooler. all models similar. 2 Remove the end covers “a” and “b” from BOTH port and starboard ends of upper and lower sections of heat exchanger tank.2L engine intercooler drain plug shown. until all water passage tubes are completely free of standing water. 1 Close seacock. water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and/or boat. Failure to do so could cause corrosion or freeze damage to heat exchanger water passage tubes. 91 . 7 Remove hose(s) at seawater strainer and drain hose(s) completely. Drain tank completely. IMPORTANT: Observe the following information to ensure complete draining of cooling system: • Engine must be as level as possible. Tighten securely. (12-14 Nm). refer to “Cleaning Quicksilver Seawater Strainer. 8 After seawater section of cooling system has been drained completely. CAUTION Avoid damage to heat exchanger and subsequent possible engine damage. Do not unplug seawater inlet hose unless a seacock is present and it is closed. 5 Remove seawater pump outlet hose from top of seawater pump and drain. NOTE: In the following it may be necessary to lower or bend the hoses to allow water to drain completely. • A wire should be repeatedly inserted into all drain holes to ensure there are no obstructions in passages.” Reconnect hose(s) and tighten hose clamps securely. CAUTION Avoid water entering boat. If boat is not fitted with a seacock. As a precautionary measure. 4 Remove the drain plug from the aft end cover of the intercooler. Tighten hose clamps securely. Empty seawater strainer. if boat is to remain in the water. attach a tag to the ignition switch or steering wheel with the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine. NOTE: D4. coat threads of intercooler drain plug with Perfect Seal and reinstall.CE382 Power Package Layup (Continued) Drain seawater section of cooling system and prepare for cold weather or extended storage following these procedures: DRAINING INSTRUCTIONS CAUTION If boat is to remain in the water. (14-15 Nm).

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perform all checks. lubrication and fluid changes outlined in Maintenance Schedules. Be certain to follow the propylene glycol manufacturer’s recommendations.DO NOT Operate Engine” and the warning that the seacock must be opened or the water inlet hose reconnected prior to starting the engine. water inlet hose must be disconnected and plugged to prevent water from flowing into cooling system and/or boat. must remain closed until engine is to be restarted to prevent water from flowing back into seawater cooling system. if so equipped.) 11 Remove seawater pump impeller for storage. if equipped.S. IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe) be used in seawater section of the cooling system for cold weather or extended storage. 8 Clean engine and coat with Quicksilver Corrosion Guard. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.CD666 Power Package Layup (Continued) Dealer should perform the remaining tasks prior to layup: 1 After draining. NOTE: Pump shown removed for visual clarity only. 2 Close seacock. CAUTION If boat is to remain in the water. seacock. 3 Clean seawater strainer (refer to “Cleaning Quicksilver Seawater Strainer”). Ease impeller off pump shaft with two screwdrivers. Remove cover and gasket. if boat is to remain in the water. A Cover and Screws B Gasket C Impeller IMPORTANT: Place a CAUTION TAG at instrument panel and in engine compartment stating that “Seawater Pump Impeller is Out . dry place. Connect an appropriate length piece of hose to seawater pump and place the other end of the hose into container of coolant mixed in step 4. wood board or a thick plastic base (Refer to battery manufacturer’s instructions. or on the ground Place on a dry. 5 Disconnect hose from seawater inlet side of seawater pump. 9 Lubricate all cables and linkages. 7 Reconnect water inlet hose to seawater pump. quarts (5. Also. Do not store on a concrete surface. Remove seawater pump cover mounting screws. check local laws about disposal of the antifreeze solution after use. inspections.6L) of antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage. then stop engine. 4 Fill a container with approximately 6 U. 93 . If boat is not fitted with a seacock. Reinstall cover for storage. or disconnect and plug seawater inlet hose. 6 Start engine and run at idle speed until coolant mixture has been pumped into engine seawater system. 10 Remove and store battery in a cool.

CE384 73522 A B C E D 2 94 71366 71366 .

6 Perform all checks on Operation Chart in the Starting Procedure column. Secure each cable clamp when connecting. 4 Bleed fuel system. 5 Install fully-charged battery. It battery cables are reversed. hold the STOP switch toggle lever DOWN while you simultaneously turn the key switch to START position for 15 seconds. 7 Pre-lubricate the engine if necessary.2L LD Engines: After not having been operated for two months or longer. do not engage starter motor for more than 15 seconds each time. fluid. and NEGATIVE (–) battery cable to NEGATIVE (–) battery terminal LAST.6L. CAUTION When installing battery. connected properly. 8 Carefully inspect engine for fuel. electrical system damage will result. D4. During this process the engine will not run because no fuel is injected. and D4. 2 Install seawater pump impeller. be sure to connect POSITIVE (+) battery cable to POSITIVE (+) battery terminal FIRST. 9 Check steering system. and tighten screws securely. IMPORTANT: Use new gasket. Install in correct position . water and exhaust leaks.2L. Allow the starter motor to cool down for one minute and repeat the above described process.Fuel System”. oil. Refer to “Maintenance . Clean battery cable clamps and terminals and reconnect cables (see CAUTION listed above). Install pump cover. shift and throttle control for proper operation.CD667 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment. This will rotate the starter motor and engine/oil pump. Refer to IMPORTANT above. Place impeller in pump and press onto pump shaft firmly. To do this. To avoid overheating the starter motor. do not install battery until all maintenance has been performed on engine. Coat terminals with a battery terminal anti-corrosion spray to help retard corrosion.wide surface on side of cam. 1 Check that all cooling system hoses are in good condition. with gasket. Start engine and closely observe instrumentation to make sure that all systems are functioning correctly. IMPORTANT: On D3. 95 . and hose clamps are tight. or connection order is reversed. A Impeller B Gasket C Wide Surface D Cam E Cover and Screws 3 Replace fuel filter. it is necessary to pre-lubricate the engine.

• Have Authorized MerCruiser Dealer service electric stop-circuit. • Replace kinked lines or blow out lines with compressed air to remove obstruction. 96 . • Position control lever in neutral. Or Cranks It Very Slowly Possible Cause • Battery switch turned off. if equipped. • Have EDI System checked by an Authorized MerCruiser Dealer. • Check and reset circuit breaker or replace fuse. Engine Will Not Start. • Stale or contaminated fuel. • Fuel line or tank vent line kinked or clogged. • If contaminated. • Throttle not operating properly. • Test and replace if bad. Fill with fresh fuel. • Empty fuel tank or fuel shutoff valve closed. • EDI System fault. • Purge fuel injection system. if fuel is present. • Check all electrical connections and wires (especially battery cables). • Air in fuel injection system. • Check throttle for freedom of movement. • Loose or dirty electrical connections or damaged wiring. drain tank. • Bad battery. • Fill tank or open valve. • Remote control not in neutral position. • Test.CD49 Troubleshooting CD361 Starter Motor Will Not Crank Engine. • Clogged fuel filters. Or Is Hard To Start Possible Cause • Improper starting procedure. • Glow-plugs or glow-plug system inoperative. • Replace filters. Remedy • Turn switch on. Remedy • Read starting procedure. Clean and tighten faulty connection. • Have pump replaced by an Authorized MerCruiser Dealer. • Open circuit breaker or blown fuse. • Faulty electrical stop-circuit. and repair or replace components. • Faulty mechanical fuel delivery pump.

Misses And/Or Backfires Possible Cause Remedy • Throttle not operating properly. • Check idle speed and adjust. • Excessive bilge water. • Check throttle linkages for binding or an obstruction. • Stale or contaminated fuel. Poor Performance Possible Cause • Throttle not fully open. Fill with fresh fuel. • Damaged or improper propeller. tributed. • Drain and check for cause of entry. • EDI System fault. • Have EDI System checked by an Authorized MerCruiser Dealer. • Idle speed too low. • Replace filters. • Clogged fuel or air filters. • Boat overloaded or load improperly dis• Boat bottom fouled or damaged.Engine Runs Rough. • Kinked or clogged fuel line or fuel tank vent line. • Purge fuel injection system. Remedy • Inspect throttle cable and linkages for operation. 97 . • Replace kinked line or blow out line with compressed air to remove obstruction. if necessary. drain tank. • Air in fuel injection system. • If contaminated. • Clean or repair as necessary. • Replace. • EDI System fault. • Have EDI System checked by an Authorized MerCruiser Dealer. • Reduce load or redistribute load more evenly.

• Replace. • Drive belt loose or in poor condition. • Clean seawater side of water/water heat exchanger. Remedy • Open. • Clean exhaust elbow. and seawater strainer. • Seawater discharge restricted or plugged. • Loss of pressure in closed cooling section. • Position hose to prevent kinking (restriction). inspect and test pressure cap. Fill system with proper coolant solution. • Remove obstruction. • Use of improperly designed hose on inlet side of seawater pump allowing it to collapse. • Coolant level low in closed cooling section. • Seawater inlet hose kinked (restricted). • Replace and/or adjust belt. • Closed cooling section dirty. Remedy • Replace. • Seawater pickups obstructed. • Replace hose with wire reinforced design. Insufficient Engine Temperature Possible Cause • Faulty thermostats. • Faulty seawater pickup pump. Clean. • Repair.Excessive Engine Temperature Possible Cause • Seacock closed. • Clean and flush. • Heat exchanger cores plugged with foreign material. • Check for leaks. if equipped. • Faulty thermostat. 98 . • Check for cause of low coolant level and repair.

• Insufficient oil in crankcase. Battery Will Not Come Up On Charge Possible Cause • Excessive current draw from battery. if equipped. Remedy • Turn off non-essential accessories. Determine cause for dilution (excessive idling. • See Authorized MerCruiser Dealer immediately for shift cable adjustment. hose or fittings of Power Shift Assembly. • Excessive oil in crankcase (causing it to become aerated). Repair or replace damaged wiring. etc. • Unacceptable battery condition. • Check and remove required amount of oil. • Alternator drive belt loose or in poor condition. using correct grade and viscosity oil. • Improper shift cable adjustment. Check for cause of excessive oil (improper filling. • Replace and/or adjust. • Check all associated electrical connections and wires (especially battery cables). If any are loose or missing.). • Loose or missing shift and throttle linkage fasteners. 99 . • Repair cut. Clean and tighten faulty connections. bad fuel pump. • Vacuum leak at shift cylinder. Remote Control Operates Hard. or kinked hose or faulty shift cylinder. • Check and add oil. • Test battery. • Straighten cable. pinched. • Have system checked by an Authorized MerCruiser Dealer. • Loose or dirty electrical connections or damaged wiring. • Obstruction in shift or throttle linkages. • Remove obstruction.Low Engine Oil Pressure Possible Cause Remedy • Faulty senders.). Remedy • Lubricate. • Diluted or improper viscosity oil. or have dealer replace cable if damaged beyond repair. Binds. Has Excessive Free-play Or Makes Unusual Sounds Possible Cause • Insufficient lubrication on shift and throttle linkage fasteners. etc. • Change oil and oil filter. • Shift or throttle cable kinked. see Authorized MerCruiser Dealer immediately. faulty fuel pump. • Check all linkages.

CA461 Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local Authorized Dealer. then contact the owner of the dealership. * Quicksilver parts and accessories are engineered and built by Mercury Marine. for any reason. EXTRA HELP 100 . special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur. Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory. The dealer has the necessary information to order parts and accessories for you should he not have them in stock. 1 Talk with the dealership’s sales manager or service manager. you cannot obtain service. the dealer requires the motor model and serial number(s) to order the correct parts. contact the nearest Marine Power International Service Center. Outside the United States and Canada. If you ever have a problem. The following information will be needed by the service office: • Your name and address • Daytime telephone number • Model and serial number for your power package • The name and address of your dealership • Nature of problem Mercury Marine Service Offices are listed on the next page. question or concern about your power package. specifically for Mercury MerCruiser sterndrives and inboards. Mercury Marine does not sell to unauthorized dealers or retail customers. CB577 Resolving A Problem Satisfaction with your MerCruiser product is very important to your dealer and to us. If this has already been done. take these steps. Only he has the factory trained mechanics. If. concern or problem that cannot be resolved by your dealership. contact your dealer or any Authorized MerCruiser Dealership. should the need for service arise. contact the nearest Regional Service Center. Mercury Marine will work with you and your dealership to resolve all problems. If additional assistance is required. Refer to the Yellow Pages of the telephone directory. Parts And Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local Authorized Dealer. When inquiring on parts and accessories. knowledge. Service Away From Home If you are away from your local dealer and the need arises for service. He knows your engine best. contact the nearest Authorized Dealer. please contact Mercury Marine Service Office for assistance. 2 Should you have a question.

Please include your daytime telephone number with mail and fax correspondence. Suite 226 Miami. call.A. Mercury Marine . Africa (32) (87) 32 • 32 • 11 Mexico. Perkins Rd.Victoria 3164 Australia Marine Power . Ontario Canada L5N 7W6 Mercury Marine Australia 132-140 Frankston Road Dandenong. 137th Ave. Middle East. 27-2 Muramatsu Chisaki-Shinden Shimizu City Shizuoka Prefecture Japan 424 Mercury Marine Singapore 72 Loyang Way Singapore 508762 (405) 743-6570 MerCruiser 3003 N.CA785 Mercury Marine Service Offices For assistance. Pacific (61) (3) 791-5822 (61) (3) 793-5880 Europe. Telephone Fax Mail United States (405) 743-6566 Canada (905) 567-MERC (6372) (905) 567-8515 Mercury Marine Ltd.S. Central America. Stillwater.Europe. Inc. 2395 Meadowpine Blvd. Singapore 5466160 5467789 101 . OK 74075 Australia. Mississauga.W. Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mercury Marine . FL 33186 U. Caribbean (305) 385-9585 (305) 385-5507 (32) (87) 31 • 19 • 65 Japan (81) 543/34-2500 (81) 543/34-2022 Asia.Japan No. or write. South America. fax.Latin America & Caribbean 9010 S.

josta saat lähempiä tietoja. contact the nearest Mercury Marine or Marine Power International Service Center for further information. Check the literature and quantities you want. cac781 Muut kielet Saadaksesi Käyttö– ja huolto–ohjekirjoja muilla kielillä. cab781 Andere talen Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient u contact op te nemen met het dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hierover. caa781 Andre sprog Kontakt det nærmeste Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings– og vedligeholdelsesmanual på et andet sprog. contact the nearest Mercury Marine or Marine Power International Service Center for information. 102 . When ordering be sure to: 1. Maintenance and Warranty Manual in another language. 2. CA781 Other Languages To obtain an Operation. 3.O. A list of part numbers for other languages is provided with your power package. Box 1939 Fond du Lac.O. List your product. ota yhteys lähimpään Mercury Marine tai Marine Power International huoltokeskukseen.D. Een lijst met onderdeelnummers voor andere talen wordt bij uw motorinstallatie geleverd.CA463 Customer Service Literature English Language English language publications are available from: Attn: Publications Department Mercury Marine W6250 West Pioneer Road P. WI 54936-1939 Outside the United States and Canada. model. Moottorisi mukana seuraa monikielinen varaosanumeroluettelo. year and serial number(s).’s). En liste med reservedelsnumre for andre sprog leveres sammen med din power–pakke. Enclose full remittance in check or money order (NO C.

cad781

Autres langues
Pour obtenir un Manuel d’utilisation et d’entretien dans une autre langue, contactez le centre de service après– vente international Mercury Marine ou Marine Power le plus proche pour toute information. Une liste des numéros de pièces en d’autres langues accompagne votre bloc–moteur.
cae781

Andere Sprachen
Um eine Betriebs– und Wartungsanleitung in einer anderen Sprache zu erhalten, wenden Sie sich an das nächste Mercury Marine oder Marine Power International Service Center. Eine Liste mit Teilenummern für Fremdsprachen ist im Lieferumfang Ihres Motors enthalten.
caf781

Altre lingue
Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza internazionale Mercury Marine o Marine Power più vicino. In dotazione con il gruppo motore, viene fornito l’elenco dei codici prodotto dei componenti venduti all’estero.
cag781

Andre språk
Ytterligere informasjon om bruks– og vedlikeholdshåndbok på andre språk kan fås ved henvendelse til nærmeste internasjonale servicecenter for Mercury Marine eller Marine Power. En liste over delenumre for andre språk følger med aggregatet.
cah781

Outros Idiomas
Para obter um Manual de Operação e Manutenção em outro idioma, contate o Centro de Serviço Internacional de “Marine Power” (Potência Marinha) ou a Mercury Marine mais próxima para obter informações. Uma lista de números de referência para outros idiomas é fornecida com o seu pacote de propulsão.
caj781

Otros idiomas
Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.
cak781

Andra språk
För att få Instruktions– och underhållsböcker på andra språk, kontakta närmaste Mercury Marine eller Marine Power International servicecenter, som kan ge ytterligare information. En förteckning över artikelnummer på andra språk medföljer ditt kraftpaket.
CAm781

Allej glþssej
Gia na apoktÞsete Ýna Egxeiρßdio Leitouρgßaj kai SuntÞρhshj se Üllh glþssa, epikoinwnÞste me to plhsiÝsteρo DieqnÝj KÝntρo SÝρbij thj Mercury Marine Þ thj Marine Power gia plhρofoρßej. To pakÝto isxýoj saj sunodeýetai apü Ýnan katÜlogo aρiqmþn paρaggelßaj gia Üllej glþssej.

103

CA752

Ordering Literature
Before ordering literature, please have the following information about your power package available: Model __________ Horsepower__________ Serial Number_____________ Year_______

United States and Canada
For information on additional literature that is available for your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine
Telephone Fax Mail

(920) 929-5110

(920) 929-4894

Mercury Marine Attn: Publications Department P.O. Box 1939 Fond du Lac, WI 54936-1939

Outside The United States and Canada
Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular MerCruiser power package and how to order that literature.

104

CD68

Owner’s Logbook
Date Maintenance and Repair Operating Hours

105

CD68 Owner’s Logbook Date Maintenance and Repair Operating Hours 106 .

CD68 Owner’s Logbook Date Maintenance and Repair Operating Hours 107 .

75308 108 .

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